So… it's been a minute…
Frankly I just haven't been too excited to write about my progress, because: A: There hasn't been much B: lots of unnecessary running around/wrong parts/no parts, and C: almost none of it has been any fun…
But when I dove into starting this thread, I committed to documenting this project - the good, the bad, and everything in between. I hate cliff-hangers. Post 'til you die.
So — fair warning: this episode is long, convoluted, disorganized, and annoying… exactly how things have been going for me… you've been warned…
This Episode: Paint Shmaint
Two trips in December and January
As the ever-eloquent Mike Tyson once said: "Everyone has a plan until they get punched in the mouth."
Well… that's pretty much been the story of my trips up to work on my car. I always head into the long weekends excited, and with a clear plan… rarely does it go as anticipated. And I reckon the last couple of trips were the worst yet - weather conditions punched me in the mouth repeatedly - and my plans staggered into the corner and threw in the towel.
This time the plan going in was to finish the tub prep by coating the rust patches that my friend Dave has finished welding.
I'd then paint the portion of the frame accessible through the empty engine bay. And if I had time, I'd put down some final paint in the tub to be ready for Kilmat.
But as mentioned, the weather punched me in the mouth.It was cold, super foggy, drizzly, and even some actual rain. We sure do need it, so I won't complain… but it didn't allow for any of the original painting plan.
So, I was forced into a quick pivot.
New priority: flywheel. I'd been kicking this can down the road… I've ogled at JT's super-light fly wheel, heard nothing but great reviews, but I asked my trusted group and the consensus was "Just get your original flywheel lightened a bit. You CAN go too light."
Flywheel Before:
My stock flywheel weighed 21.7 lbs. Dave Rebello, among others, recommended 15-16 lbs for me and my stroker - which is right about half-way between JT's flywheels and stock - so I decided to try that for now. If I feel the need later, and budget permits, I'll pop for one of those beauties.
Anyway… all of this began on a Thursday, and I made an appointment with a well-respected speed shop about 30 minutes away to drop the flywheel off on Friday morning — and have it lightened, surfaced, and balanced.
Trying to kill two birds, I also asked if he could do a quick resurfacing of my crusty rusty front brake rotors to pick up end of day, Friday — we were to trailer the car from my brother's shop to his house for the weekend, so it was imperative that the car be rolling onto the trailer by the end of Friday. Off came the rotors and I drove those and the flywheel down Friday morning.
When I got there, we discussed the plan for the flywheel — he's done a ton of these, and I realized that he's reassuredly conservative — making sure there's no chance of taking too much off and weakening it. He figured to turn off about 5-6+ lbs, getting it down to 15-16 lbs. Perfect. I only asked that he keep the original "JAPAN" stamp — which he said he normally does anyway.
So, I left the flywheel and the brake rotors and headed back north, whistling a happy tune, planning to pick up the rotors in a few of hours. In the meantime, I'd go buy more paint where I bought the paint for my engine bay. I got there just after they closed for lunch (gotta love old-school), so I toodled around and found some chicken wings for lunch, made it back to the paint store, picked up the paint, and decided to drive back to my brother's shop and get some stuff done before picking up the rotors later in the day. As I pulled into the shop lot, the machine shop called and said he was very sorry, but wouldn't be able to do the rotors that day.
Shoooooot! But with "i's" instead of "o's".
So I had to immediately hustle back down and scramble… because the car HAS TO roll. I drove all the way back down there, and on the way called another machine shop I know who said they could do it, grabbed the rotors — and these guys were gems — they saved my tail by turning them very quickly, just to get the surface rust off. Revitalized rotors in hand, I raced back to the shop and worked like mad to get them back on the car before my brother closed up shop. I finished in the dark while he made a run to the store… and when he came back, we were able to roll the car on to the trailer. Phew. It was a just a fustercluck of a day… a lot of driving and very little actually accomplished. A frustrating way to start the weekend.
Sidebar: later in the weekend, talking with one of the gurus, I was told that turning the front rotors or the rear drums is "stupid"… that's me, I guess. Sigh. He feels that the materials are so stout that it's unnecessary, and normally just need sanding to get the rust or corrosion off.
But, because I'm stupid, I turned the front rotors… and you'll just have to trust me, but they ended up looking sweet, I didn't take a photo in the rush to reassemble in the dark.

Rotors Before.
Saturday morning oozes in like whatever is seeping from my rear differential: thick, wet, dark, and cold. I will not be painting today.
Soooo, what to do? I reckon it's time to saddle up and tackle another thing I've been avoiding — it was time to look at the rear brake situation!
Shiver.
Rear brake assessment: from the surface, both sides have been untouched and unused for 30 years or so, and they look the part. Dirty. I enlisted my nephew to help me pull off the drums, but being impatient newbies, we ended up taking out the entire rear axle.
Heck, it was actually very easy, needed to be done anyway, and revealed a leaking rear axle seal on the passenger side.
So, then we took off just the drums. Both are rusty and rough, but they actually don't look beyond-repair-terrible, although the passenger side is loaded with gunk. A ridiculously sharp-eyed Mike Young recognized from a crappy cell phone image that the previous owner had put in that rear-seal backwards.
Rear Axle and Brake Drums Before Photos:
Thinking that it would be nice to just 'start anew', (before hearing from Guru) I brought the drums down to the local Big O Tires (who have been great in every way to this point) and asked them to turn them. However, they wouldn't do it because there is some weird, hard-to-find info out there that says the max inside diameter is 9.04", mine were 9.05"… so I was denied.
Sidebar #2: This measurement appears to be a common point of confusion — from my quick research, the published stock measurement is published as the same as the max Inside Diameter (???)… I'll keep looking, but whatever info is out there is not sufficient for the Big O/O'reilly/Autozone techs…
Call to action: Any of you Datsun Illuminati would be doing the Roadster Community a big favor by clarifying the Inside Diameter - stock/untouched measurement vs. the max allowable. I'll donate a sixpack / fancy coffee / smoothie / kombucha / soda / etc. to the cause.
First Tallboy goes to @unklpat for doing a bunch of research on the fly as I was trying to talk Big O into turning them.
With no commercial options, and the need to do SOMETHING productive, I went all hand-to-hand-combat on 'em. A lot of scour pads, sand paper, degreaser, tequila, and knuckle-busting got them looking pretty darn good.
Rear drums after:
And since I had all of this apart, I decided to go get new rear seals, front bearings, and rear brake shoes. Picked up the parts, got back to the car, and every part was wrong. Complete wiff. That's the other problem with having to switch plans on the fly, on the weekend… not easy to get your hands on parts to fit a 50 year old Japanese car. So, I was stalled again. I tried to heat up the garage and painted the rear brake back plates or whatever you call those. Huffing paint eased the pain a bit.
This is how the weekends went… just one setback after another.
Now, as I'm writing this many weeks later… I'm trying to recall the sequence of mostly annoying events… but it's a big blur, the fog of war. I was at my lowest point in this whole saga. Demoralized and wondering if I could ever finish this thing. It was overwhelming, and it actually stopped being fun. I know I'm not alone, I've seen the "Selling a project because I don't have the time/money/energy/desire/interest anymore" posts. I was almost there.
But… since then, I've rebounded a bit, in large part to what I see on this forum… ridiculously experienced people generously offering advice and encouragement, excited and enthusiastic folks just joining in, inspiring detail work by guys like @spriso, and even guys like @funkaholik always bragging about the impeccable work they do. Hee hee. Anyway, it helps keep me going.
Alright, since this post has been boring as heck so far, no sharks or recipes, I'm going to spare you the disheartening details and all of the crushing defeats… I'll just list some random stuff, the crappy bits, and the few highlights of what I actually accomplished.
In no particular order —
Gun cases are an excellent mode of transport for your freshly chromed windshield frame. Pro-tip: put a box of bullets in there, because if you're not actually transporting dangerous stuff, the airlines charge you for oversize luggage. If you have deadly weapons, they waive the fee. Crazy but true.
Oh! Here is the highlight of the trips… I finally took out my original 4-speed transmission. I called @andyb. Andy loaned me some suspension parts, and I know that he has a couple of Roadsters, so I offered him my old transmission that he can use for parts if needed. I drove down to drop it off and checked out his project car - which is amazing - that thing is going to be awesome. Really top notch. He's a great guy with a great setup. Andy also convinced me (and offered to help!) to do a 'minor-rebuild' of my 5-speed transmission before I put it in. I've been reluctant, but I agree that it's the smart thing to do. Just one more task, but how great is Andy to offer to help!
I also took apart the rear brake cylinders to rehone and rebuild. But that didn't go so good either. They're too far gone and need to be re-sleeved. More time and money. Aaargh.
I flipped the rear seal (buy a $7 seal puller, trust me).
I cleaned up the rear brake line splitter thing and installed new stainless brake lines and stainless flexi hose.
I tried unsuccessfully to remove the wiper nuts — and may have ruined the entire assembly… stripped the part on the inside of the car and messed up the nuts. And they're impossible to find. Yay. This pissed me off and almost tipped me over the edge.
With one good weather morning I worked on my fuel tank. A while back I had it boiled and lined. I then took it down to bare metal, and on the one not-too-cold day I was able to paint it… Cool, right? But, that's when I noted there is a hole in it. I think it fell on sharp gravel and punched a hole like a tin can. So, now I need to get that welded. Yay.
Gas Tank Before:
Stripping it down:
Gas Tank After:
I did put my front calipers all together with new stainless lines. They turned out really sweet - a rare win.
Went on a nice hike and saw this really, really nice buck and had fun just watching and stalking and photographing. Peaceful.
And some turkeys.
Meals are always a highlight - hand-caught lobster, elk liver pâté, and venison from last year's buck were all amazing. I gotta keep my brother and his family well-fed for putting up with me. I don't ever take an animal for granted. It really is special and fulfilling to share game with people who appreciate it. The meals are a bit of a high note after a few crappy days.
So, that's where I am… and now that I've recovered and my ambition is slowly coming back, I'm looking at all my new pretty chrome bits and going to work on that stuff.
Sorry for the long, depressing post. But… I did warn you.
UPDATE Flywheel After:
