Imported From Japan: Z20 Soarer Rebuild In Kentucky, Part 1

"Bird" (Bird)
08/18/2014 at 10:03 • Filed to: Imported From Japan, Blog

I can't say I'm happy about the circumstances, but I recently spent a week working on our Soarer Aerocabin with my dad and grandfather. I've always lived several hundred to several thousand miles away, so it's not something that I've had the chance to do very often. It made for a very memorable end to a stressful road trip.

Since our car wasn't performing at it's peak, we ended up needing some help along the way. From family and friends to total strangers, there's no way we would have made it to our destination without them.

Notable mentions include our friends in Arizona, my dad and cousin for driving 5 hours through the night to pick us up from the final breakdown, my sister and her boyfriend for helping get the car unloaded at my grandparents, a guy in a W124 Mercedes who gave us some coolant somewhere in Oklahoma, and the friendly people at the Days Inn in West Memphis that gave us a great price on a room, and let us check in at 8am to sleep it off after we drove through the night to make it through Arkansas without overheating.

Before I get too far into the teardown story, I want to talk a little bit about the garage I'm working in. As a kid, my parents shipped me off to my grandparents for most of the summer. This is the garage where I oiled the chain on my bike or cleaned sparkplugs after I fouled them trying to cold start my three wheeler.

It's pretty basic, just a pole barn really. It hasn't changed much since I was a little kid. Dirt floor, metal siding, and posts made from trees felled on the property. Supposedly, the metal siding was leftover material from the Corvette factory.

I can't say for sure if the siding really was from the Corvette factory, but the garage fridge was made by GM.

It has one really nice feature though, a steel beam that runs over the middle bay. Hanging from the beam is the differential hoist we're using. It's older than me…and there's a good chance it's older than my father too. It's been used to pull a lot of motors…and skin at least one goat. That was a shock to see when I transferred their old 8mm films (why that was film worthy, I have no idea...) Although, I'm sure people have seen more disturbing things when they transferred their parents or grandparents old movies to dvd…

If you !!!error: Indecipherable SUB-paragraph formatting!!! , you'll know we have a blown head gasket. It's a fairly common problem for the 7M motors. They tend to go around 75k miles and that's right about where we are. They go out slowly, and ours was likely blown since we got the car. It made it all the way from LA to West Memphis only showing the faintest signs of a problem. A lot of people blame the factory head bolts for it, but I'm not so sure. The factory torqued them to 56ft-lbs, and later revised it in the service manual to be higher. While they may contribute, I think the real issue is the head gasket itself.

Stock it uses a composite design, and we'll be switching to a full metal design to better cope with the cylinder pressures of a turbo engine. That and ARP head studs should solve the problem for good. Using a metal head gasket requires a different surface finish to the head and block to seal correctly, so that means full rebuild time. We already had !!!error: Indecipherable SUB-paragraph formatting!!! rebuild our turbo, and I've replaced every wear item I can get my hands on…ball joints, bushings, shocks, brakes, etc. After this it'll be completely mechanically restored.

Here you can see the extent of the damage on cylinder #6. The gasket's metal ring deformed around the top of the cylinder, and eventually broke. Over time the gasket eroded to the point where exhaust gasses could make their way into the water jackets on the right. Initially it's only a very slow leak of exhaust gas into the water jacket. This slowly puts 'air' in your cooling system diminishing it's ability to cool. In our case, so slowly that you had to drive it a couple hours across the desert in July to have any real issues. When it gets worse, you'll end up with coolant flowing into the cylinder when you turn the car off. Hence the water damage to the piston, and the unseen damage to the cylinder wall. Having coolant in the cylinder when the engine starts causes the oil film in the bore to be steam cleaned, and the piston rings eventually gouge the cylinder wall.

We actually had two leaks. This is cylinder #1. It's not as bad as 6, but still blown out. We drove over 3000km's with a tiny leak. We didn't so much as stumble all the way from LA. It wasn't until we reached Memphis that it started to show signs of low compression.

While we've got the car apart we decided to go ahead and rebuild the transmission and the rear differential. We noticed the input bearing was whining just a little on the highway, and the LSD I swapped in has a little more play than I would like. Every time I take a car apart I get a case of the 'might as wells'…might as well do it now while it's apart…

We took all the parts to the machine shop, placed another big order with !!!error: Indecipherable SUB-paragraph formatting!!! , and then I left the car under the watchful eye of my grandparents German Shepherd, 'Betty'. That was a couple weeks ago, and we're back in Kentucky now to put it back together. It's going to be a busy couple of weeks. As well as working on the Aerocabin, we have to finalize our dealership setup. We need to rent a building/lot, file a bunch of paperwork, and apply for our dealer's license.

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I'll leave you with the timelapse of our tear down. If you want to see even more photos check out the !!!error: Indecipherable SUB-paragraph formatting!!! . I hope everyone's enjoying reading about our saga. It's a lot of fun sharing it, and we can't wait to be able to write about it as a licensed car dealer in the state of Kentucky.

We are Bird (me) and Corinne ( !!!error: Indecipherable SUB-paragraph formatting!!! ). We imported two cars from Japan and are working to set up our import business. We're writing about the experience on Oppositelock. To see all of the updates search the tag !!!error: Indecipherable SUB-paragraph formatting!!!

For more photos check out Bird's website !!!error: Indecipherable SUB-paragraph formatting!!!

Update! Check out our company's website !!!error: Indecipherable SUB-paragraph formatting!!! . You can also follow us on !!!error: Indecipherable SUB-paragraph formatting!!! and !!!error: Indecipherable SUB-paragraph formatting!!! to get the updates on our car builds, car shows, and road trips.

DISCUSSION (36)

quarterlifecrisis > Bird
08/18/2014 at 09:22

Cool is my initially reaction, but that requires some expansion. While the problems certainly aren't a good thing - a road trip where things go haywire can be good. It at least makes for a helluva story. And getting to work on things with the family members that get you into the hobby can be enjoyable as well. I'm 700 miles from my dad's place, which is where all the project vehicles live. I miss being able to bomb up the road a few hours to spend a weekend working on things, and learning more each time.

Best of luck on the reassembly, and your drive back west...unless I missed something and you're relocating back east. However it works, cheers.

banjo cat ghost of oppo past > Bird
08/18/2014 at 09:23

I wanna know whats up with those two conversion vans...*licks lips*

FKA-RacecaR > Bird
08/18/2014 at 09:44

It's a lot of fun sharing it, and we can't wait to be able to write about it as a licensed car dealer in the state of Kentucky.

So...a licensed IMPORT car dealer in the state of Ky? Because that would be awesome. because I am in southern Indiana and will be looking to import an Evo IV once they are available.

Bird > FKA-RacecaR
08/18/2014 at 10:13

That's correct! We'll be bringing in cars from Japan and Europe.

FKA-RacecaR > Bird
08/18/2014 at 10:14

Awesome!

Bird > quarterlifecrisis
08/18/2014 at 10:15

It's definitely a helluva story...

We'll be driving it back west to go to the Supra's in Vegas show on Sept 19th. After that though it will go back to Kentucky. We're relocating so we can start our import business in a state other than California. California doesn't like imports...

Bird > banjo cat ghost of oppo past
08/18/2014 at 10:16

The one in the garage was my parents when I was younger...no mini-van for my mom...

The one outside is a recent addition to their fleet. My grandparents are both in electric chairs now, and needed a van with a lift.

BiTurbo228 - Dr Frankenstein of Spitfires > Bird
08/18/2014 at 10:21

I wish I had the funds at the moment to 'might as well' all the little problems on the Jaaag.

I will do eventually, but for now I've just got to chip away at the free ones before sorting out things like a full refresh of all suspension bushes, new rear shocks, new wheel bearings etc.

signintoburnerlol > Bird
08/18/2014 at 10:32

Kentucky is too far to me, i might have to check out this importing dealership when it is up and running.

FriskyDingo > Bird
08/18/2014 at 10:37

Welcome to JDM ownership its very wallet intense!

quarterlifecrisis > Bird
08/18/2014 at 10:38

Ah. I see. I was going to question the import business in Kentucky, seems that being closer to a port would be beneificial...but....California.

Mathias Rios > Bird
08/18/2014 at 10:41

I love your posts and look forward to them! Good luck on your dealership!

Kanaric > Bird
08/18/2014 at 11:58

1JZ not available yet at that year? I think they were from 89+. Good choice. Was considering one of these myself but imported a skyline instead.

1JZ Soarers are far better than MK3 supras we got in America. You can get it lighter, with a slick top setup and the 1JZ is basically a 2JZ with a bit more turbo lag. Just as stout, just as awesome. These Soarers also use MK3 Supra parts mostly so parts for them are easier to find than some things are for a Skyline.

Kanaric > signintoburnerlol
08/18/2014 at 11:59

Fortunately there are several alternatives including not using a middle man at all.

Bird > Kanaric
08/18/2014 at 12:10

Unfortunately Aerocabins didn't get the 1JZ. Supposedly it has the updated crossmember that makes swapping a JZ motor in easier.

We've had pretty good luck with parts so far. Being mechanically the same as a Supra makes it fairly easy. We did get caught off guard by the brakes. The Soarers had smaller rotors but used the same calipers and pads. I got some MK3 caliper brackets at the junkyard so we could use off the shelf rotors from now on.

The only other issue is the RHD vs. LHD...heater hoses have to be ordered from Japan or trial and error at the parts store.

Bird > quarterlifecrisis
08/18/2014 at 12:13

Yeah, there's advantages and disadvantages to being in the Midwest...I also have family here, so that's part of it too.

Bird > signintoburnerlol
08/18/2014 at 12:15

Once we're up an running feel free to stop by. We also plan to be active and go to as many nearby car shows as possible.

Where are you at?

Bird > Mathias Rios
08/18/2014 at 12:16

Thanks!

Bird > BiTurbo228 - Dr Frankenstein of Spitfires
08/18/2014 at 12:17

You've also got the 'Euro tax' to deal with on parts...I don't envy you that...

JEM > Bird
08/18/2014 at 12:39

Awesome, but what are under the covers in the barn!?

Bird > JEM
08/18/2014 at 13:11

That's a low-mile 70-something Lincoln...I can't remember what year...it sat in my great aunt an uncles warehouse for a couple decades after they stopped driving it, then they gave it to my grandfather.

It's huge...the hood is 2 and 1/2 feet longer than the soarer hood...and it's long!

JEM > Bird
08/18/2014 at 14:07

I'm guessing probably a Mark V Continental. My dad had one and yes, the hood goes on forever.

signintoburnerlol > Kanaric
08/18/2014 at 16:13

True, but sometimes it's just best to through a middleman.

signintoburnerlol > Bird
08/18/2014 at 16:14

Im in Long Island, New York. Bout 12-14 hours away. That seems like a long drive but anything below 20 is easy game.

Dsscats > Bird
08/18/2014 at 17:41

*please say Az please say Az please say Az*

Actually, that could be good because theres pretty much no inspection

Bird > JEM
08/18/2014 at 18:53

Yep, '78 Mark V. 54k miles...2 owner too.

Bird > signintoburnerlol
08/18/2014 at 18:56

I'm the same way...I've got no problems spending a day on the road.

We're going to be fairly close to the corvette museum too...you could make a great road trip out of it!

Bird > Dsscats
08/18/2014 at 18:59

No...Kentucky. We'll still be around LA though...

Dsscats > Bird
08/18/2014 at 19:10

Bummer, but good, I guess.

Bird > Dsscats
08/18/2014 at 19:17

Time to put some miles on that Z!...Road trip!

Dsscats > Bird
08/18/2014 at 19:32

Just cracked 53k the other day. With any luck, I'll be in an E39 touring for my next road trip.

As Du Volant > FKA-RacecaR
08/21/2014 at 11:13

Where in Kentucky? I grew up in Louisville and visit fairly regularly.

No funds to buy anything but it'd be neat to stop by and check out your shop sometime.

FKA-RacecaR > As Du Volant
08/21/2014 at 11:30

I think that was meant for Bird, and not me?

As Du Volant > FKA-RacecaR
08/21/2014 at 11:44

Yes it was, thanks Kinja.

As Du Volant > Bird
08/21/2014 at 11:45

Where in Kentucky? I grew up in Louisville and visit fairly regularly.

No funds to buy anything but it'd be neat to stop by and check out your shop sometime.

Bird > As Du Volant
08/22/2014 at 00:47

We're near Bowling Green. We're trying to rent an old gas station in Brownsville that my grandfather operated as a DX station in the late 50's.

Once we're up and running you're welcome to stop in!