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Thread: Honey Badger the Y60

  1. #91
    ......... MB's Avatar
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    Crikey, that looks Brilliant BZ Mate


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    BrazilianY60 (16th November 2021)

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  4. #92
    Patrol God mudnut's Avatar
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    That is a great colour and the finish is excellent.
    My advice is: not to follow my advice.

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    BrazilianY60 (16th November 2021)

  6. #93
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    Door Hinges

    All the door hinges had some severe play on it. And I really mean ALL the 12 hinges!

    Someone suggested me to take them to a certain shop specialized in in door adjustments. I took only the second row hinges (4) for a service test, as I was a bit skeptical about the shop appearance not inspiring me much. They worked the hinges and returned them on the next day.

    What they have done: they POORLY grinded down (as can be seen in the pictures) an old hinge pin they had laying around to match the worn bushing and tacked it to the hinge "C channel". Then, to take out the extra play of the worn bushing height, they added a copper washer. I must admit it does work, no play at all right now, but damm it, what a dirty work! That is light years away from my OCD demanded quality control levels! I decided to use them for the time they last and control the impulse of having it redone.

    20200912_203217.jpg 20200912_203220.jpg 20200912_203242.jpg


    Front row hinges were a different story. Took them to the machinist that did all the suspension poly bushings and there the job was executed like a piece of art. The hinges were taken apart, the parts that were clearly bent were flattened, new bronze bushings were turned. And instead of making the bushings ID to match the original pins, he even made new pins to the precise measure of the old one taken at a section not driven by the bushes, so "his work is not influenced by any worn part". What a pro. Here you can see the result of his work.

    20200912_202945.jpg

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    For the rear/barn doors hinges it was a no brainer. Left them on the machinist as well. Here you can see how bad the play was between pin and bushing when the hinges were disassembled:





    And here is the final result for the barn doors hinges.
    20201216_184244.jpg


    The front row hinges were also missing their springs. I used the same technique I used to make the parking brake cable: printed a picture of an OEM hinge unit and compared the measurements with my real one to come up with a scale factor, and from there, I took the closest assumption I could take about the number of turns, wire diameter, etc. Found a local spring factory and ordered some made to my numbers.

    20201203_114754(1).jpg

    20201203_114812(1).jpg

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    Here you can see the new springs working. I am pretty happy with the result.
    Honey Badger Y60 build thread
    1997 Blue Nissan Patrol Y60 blacktop TD42 - Honey Badger
    1997 Red Suzuki Samurai Canvas Top SJ413 - Tatui
    2005 White Toyota Landcruiser FZJ105 - Stormtrooper

  7. The Following 5 Users Say Thank You to BrazilianY60 For This Useful Post:

    Cremulator (15th December 2021), MB (16th December 2021), mudnut (15th December 2021), TimE (15th December 2021), Touses (15th December 2021)

  8. #94
    Expert BrazilianY60's Avatar
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    Wheel wells undercoating

    Wheel wells were somewhat in good condition. Front-left side had a crack that was nicely welded and sanded down but that's all.

    20200718_134042.jpg 20200718_134105.jpg

    20200815_183726.jpg

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    Cleaned them all, applied some wash prime on any exposed metal part and then coated them all with a product called Siltex 400. It is a rubberized/urethane thick coating that both protects the sheet metal from rocks and debris and sound deaden the wheel well. It is marketed as "body protector" and you use a plastic disposable paint gun to apply it, because it will clog the gun if you left it dry for a few minutes. My gun is still good to use as I have cleaned it good right after applying the product, but the idea with the disposable one is not to risk a good paint gun with it.

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    Last edited by BrazilianY60; 15th December 2021 at 12:46 PM. Reason: Added pictures of the cracked well
    Honey Badger Y60 build thread
    1997 Blue Nissan Patrol Y60 blacktop TD42 - Honey Badger
    1997 Red Suzuki Samurai Canvas Top SJ413 - Tatui
    2005 White Toyota Landcruiser FZJ105 - Stormtrooper

  9. The Following 4 Users Say Thank You to BrazilianY60 For This Useful Post:

    Cremulator (15th December 2021), MB (16th December 2021), TimE (15th December 2021), Touses (15th December 2021)

  10. #95
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    Front Fenders

    Front fenders required some beating to get into shape. One of them wasn't the car original anymore and curiously it was from a Patrol without the corner light, and the hole for it was clearly hand cut.

    Weekend arrives, sand, prime, store, repeat...

    20200718_124921.jpg

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    Weekend arrives, sand, prime, store, repeat...

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    Weekend arrives, sand, prime, store, repeat...

    20210424_172343.jpg

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    Applied that same Siltex 400 used on the wheel wells to the fenders, despite them being protected by the OEM plastic wheel well covers and not being supposed to be exposed to rocks and debris. I had product left over, and it does sound deaden the panel, so why not...

    20210522_164108.jpg

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    Honey Badger Y60 build thread
    1997 Blue Nissan Patrol Y60 blacktop TD42 - Honey Badger
    1997 Red Suzuki Samurai Canvas Top SJ413 - Tatui
    2005 White Toyota Landcruiser FZJ105 - Stormtrooper

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    Cremulator (15th December 2021), MB (16th December 2021), mudnut (15th December 2021), PeeBee (15th December 2021), Touses (15th December 2021)

  12. #96
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    Doors

    All doors had some kind of bend or kink from the outside. From the inside, all passenger's doors were OK, driver's door was broken in a couple of places, small barn door was OK, tire carrier barn door was damaged in more then one way, with cracked spot welds, with a thick but totally crooked reinforcement plate torch welded to the inside.

    Passenger's doors
    20190411_184519.jpg

    20190419_153833.jpg

    Driver's door
    20190411_181309.jpg


    Took off all the doors for the necessary panel beating everywhere. The driver's door was welded on the inside panel where needed and here one comment: what a surprisingly thin sheet metal! The tire carrier barn door had the crooked reinforcement removed, panels were beaten back to place until they properly seat on the internal OEM reinforcements. Everything was squared/aligned before remaking the spot welds everywhere and some extra weld beads were laid on the sheet to internal structure places that hold the spare tire weight.

    Than it was the "new weekend, sand, prime, store, repeat" all over...

    20200912_163745.jpg

    20200926_184140.jpg

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    20201010_190934.jpg


    New weekend, sand, prime, store, repeat...

    20201114_145517.jpg

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    20201114_155316.jpg 20201212_173551.jpg


    New weekend, sand, prime, store, repeat... x1000 LOL!

    20210123_160453.jpg

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    We have also sprayed the inside of the doors with Siltex 400 for some level of sound deadening, but I have plans since the beginning of this restoration to do proper sound deadening techniques to the doors, like stuffing butyl rope between the safety crash bars and the sheet metal, applying butyl metallic tiles to the sheet metal, etc. That will come at the proper time.

    20210529_125451.jpg

    We then had the doors installed and adjusted/aligned to prepare for the final sanding and get ready for all the masking required for a two color job. I was pretty excited with the way the alignment came out.

    20210626_170825.jpg

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    Honey Badger Y60 build thread
    1997 Blue Nissan Patrol Y60 blacktop TD42 - Honey Badger
    1997 Red Suzuki Samurai Canvas Top SJ413 - Tatui
    2005 White Toyota Landcruiser FZJ105 - Stormtrooper

  13. The Following 5 Users Say Thank You to BrazilianY60 For This Useful Post:

    Cremulator (16th December 2021), growler2058 (16th December 2021), MB (16th December 2021), mudnut (20th December 2021), Touses (16th December 2021)

  14. #97
    ......... MB's Avatar
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    Fair Dinkum (Great Aussie Gold) you are an absolute Meticulous Champion BZ Mate


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  16. #98
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    Accessing the brake booster situation

    Quote Originally Posted by BrazilianY60 View Post
    ...when I saw the car, I noticed the brake booster/master cylinder were adapted from another truck available in Brazil.
    Quote Originally Posted by BrazilianY60 View Post
    The booster is still a bit of a mystery. It does look equal to Y60 brake booster pictures I see online, but it has a part number that I checked and belongs to a Nissan Frontier truck (which is available in Brazil, BTW). On Partsouq they are not the same part number though. Maybe it was already adapted on the wrecked car? Who knows... Maybe you good fellows can tell me about you being using Frontier boosters on Patrols...
    Time to do some body work on the firewall, so it was time to access the brake booster situation again. The car came with an adapted brake booster from a local Chevy C10 truck from the 80's. The booster seemed to be somehow shorter and then the lip of where the firewall upper and lower sheet metal sections meet was hammered to make it fit. Time for a fix...

    This is the booster that came out. Note the stack of washers used to do spacing to some degree. What a rattling can of loosen parts, LOL. I can only imagine how silent my Patrol will be when I sort out all the crap stuff that has been done to it. Also note the weld at the tip of the shaft. It seems to have been shortened. Canīt complain about the brake pedal position though, it was spot on when driving.
    20210918_161520.jpg

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    This was the firewall situation. The goal was to fix that lip on the sheet metal but I was surprised to realize that the firewall booster holes were also fckd-up to fit the adapted booster, something that honestly never occurred me. I was naively thinking boosters bolt pattern were somewhat of an industry standard.
    20210918_161542.jpg 20210918_161545.jpg

    But wait... the firewall is sandwiched between the booster and the brake pedal bracket... if it is like this on the engine bay side, the cab side must have been fckd-up as well, right?
    20210918_161552.jpg 20211002_110014.jpg

    Here is an OEM pedal side by side with the "creative people" pedal.
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    20210925_124941.jpg

    The lip and the sheet metal with the offending holes were beaten back to place.
    20211002_115429.jpg 20211002_115438.jpg
    Honey Badger Y60 build thread
    1997 Blue Nissan Patrol Y60 blacktop TD42 - Honey Badger
    1997 Red Suzuki Samurai Canvas Top SJ413 - Tatui
    2005 White Toyota Landcruiser FZJ105 - Stormtrooper

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    MB (18th December 2021)

  18. #99
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    Accessing the brake booster situation (cont.)

    Here you can see a comparison between the adapted booster with an OEM unit. The adapted one is quite smaller in diameter (and so in effective diaphragm area which is what provides the force factor) and smaller in volume (which influences in the "amount of vacuum" available for consecutive brake pedal pressings. The pedal was hard before, but not as hard as if there wasn't any servo assistance. With the OEM unit being such a larger area as it is, I have high hopes for the car breaking behavior after I am done with this.
    20211216_093752.jpg


    The OEM booster also has this aluminum spacer to space it from the firewall. Remember the hammered sheet metal lip? I guess that happened with Nissan engineers as well, LOL. It was very handy, being a removable part, to be used as a template for creating an adapter plate to fix the booster mounting holes on the firewall.
    20211216_093909.jpg

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    20211002_122142.jpg 20211002_123824.jpg

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    Now, comparing the OEM Nissan Patrol booster with the OEM Nissan Frontier booster I got from Paraguay back in 2019. Exacly the same diameter, exactly the same volume, should provide the same braking experience as the Patrol unit. Note that the booster to firewall studs are more then double the length on the Patrol unit to account for the spacer. Also, note the pedal pressing shaft on the Frontier unit being fairly longer.
    20211216_093857.jpg

    Trying to understand the reasons behind such differences, I started searching online for pictures of the Frontier unit. It turned out, that the unit I got from Paraguay back in the day, was not complete. The Frontier unit actually uses an spacer as well, much longer, with its own mounting studs on the firewall facing side. That was the reason for the shorter studs on the booster unit, as they didn't need to reach the firewall but rather, just reach the spacer. Also, note that there are no threads left on the booster studs once the spacer is in, so there was no way for me to use my Paraguay unit with the OEM Patrol spacer.
    20211001_132937.jpg

    20211216_093932.jpg


    I ended up buying another used Nissan Frontier booster, this time locally and complete with the spacer.

    It turns out that the mounting face to pedal clevis pin distance of the Patrol and the Frontier units are exactly the same, with the same amount of adjustment threads on the shaft still available for fine tuning.
    20211216_094113.jpg

    20211216_094227.jpg


    And this is how the Nissan Frontier booster looks on the Patrol firewall, with its larger spacer. Good enough for me and now I am confident that it is an easy fix whenever I need (I also have an spare booster from Paraguay )
    20211002_113223.jpg 20211002_113215.jpg


    Now back to the firewall fix. I have drilled 4 more holes to the adapter plate for plug welds. Aligned the plate with some screws, welded, primed and seam sealed it all.
    20211002_141527.jpg 20211002_144551.jpg

    20211002_144604.jpg 20211002_173114.jpg

    20211002_173123.jpg
    Honey Badger Y60 build thread
    1997 Blue Nissan Patrol Y60 blacktop TD42 - Honey Badger
    1997 Red Suzuki Samurai Canvas Top SJ413 - Tatui
    2005 White Toyota Landcruiser FZJ105 - Stormtrooper

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  20. #100
    Expert BrazilianY60's Avatar
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    BTW, I am going to change my signature to Booster Collector, LOL.

    20211216_093734.jpg
    Honey Badger Y60 build thread
    1997 Blue Nissan Patrol Y60 blacktop TD42 - Honey Badger
    1997 Red Suzuki Samurai Canvas Top SJ413 - Tatui
    2005 White Toyota Landcruiser FZJ105 - Stormtrooper

  21. The Following 6 Users Say Thank You to BrazilianY60 For This Useful Post:

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