boosted300's RB-swapped 1978 Datsun 280Z

boosted300 · 280Z (S30)

10-page write-up

boosted300's RB 240Z

Read the full write-up at boosted300's RB 240Z ↗

An RB25DET-swapped 1978 Datsun 280Z rebuilt for boost and AC

boosted300 bought a part-finished RB25DET-powered 280Z and spent years sorting out problems left by the previous build, from a botched CV axle to a melted wiring harness, while also fitting factory air conditioning and upgrading the turbo system. The thread documents repeated troubleshooting, a rust repair on the chassis, and multiple dyno sessions chasing reliable power.

Specs

As stated in the original write-up.

Engine: Nissan RB25DET inline six, turbocharged
Turbocharger: Garrett GT35 turbine housing, later changed to .82 A/R
Fuel injectors: 1200cc RC Engineering injectors
CV axles: DriveShaft Shop custom CV axles built for horsepower goals
Water pump: N1-style replacement water pump
Peak power: Best recorded 419 hp at 19 psi with earlier internal wastegate setup
Ignition: Platinum Racing Products coil pack conversion kit

Parts used

Parts named as used in the original write-up, grouped the way the Parts page groups them. Where one of the shops we index lists the same thing for this car, it is shown underneath with a link to the shop.

Engine 1

RB25DET exhaust manifold and GT35 turbocharger
Original turbo setup with stock manifold and .63 A/R housing, later replaced
In the shops
Turbocharger Elbow to Inlet Manifold Gasket ↗Motaclan Limited· £1.34 GBP

Fuel & Ignition 2

RC Engineering 1200cc injectors
Used for fuel delivery, noted by tuner as outdated and imprecise
In the shops
DeatschWerks Bosch EV14 1200cc Fuel Injectors (Set of 6) ↗JDMuscle — Mazda MX-5· $819.00 USD
DeatschWerks Bosch EV14 1200cc Fuel Injectors, Set of 4 - 92-00 Civic/91-01 Integra ↗JDMuscle — Mazda MX-5· $569.00 USD
Platinum Racing Products coil pack kitPlatinum Racing Products
Installed to convert the ignition system, including bracket, coils and harness
In the shops
Clutch Kit (AP Automotive Products) ↗Moss Motors – Triumph TR6/TR250· $291.75 USD
BC Racing Coilover Kit - Kia Rio UB (2012-2017) ↗Paramount Performance· $1,068.17 USD
BC Racing Coilover Kit - Kia Rio DC (2001-2002) ↗Paramount Performance· $1,015.50 USD

Cooling 3

Bell intercooler core with custom end tanksBell
Replaced the McKinney intercooler to fit around the new AC condenser
In the shops
Bell Exhaust Stainless Steel Exhaust System ↗Moss Motors – Triumph TR6/TR250· $340.00 USD
Bell Exhaust Stainless Steel Sport Exhaust System ↗Moss Motors – Triumph TR6/TR250· $340.00 USD
Bell Exhaust Stainless Steel Standard Exhaust System ↗Moss Motors – Triumph TR6/TR250· $505.00 USD
N1-style water pump
Installed as a replacement after discovering the claimed N1 pump was not present
HPS silicone couplers and aluminum intercooler piping
Used to construct new intercooler plumbing
In the shops
OVERTAKE Intercooler Y-Pipe to Turbo Coupler ↗JDMuscle — Mazda MX-5· $50.00 USD

Gearbox & Drivetrain 1

DriveShaft Shop custom CV axlesDriveShaft Shop
Rebuilt and remade to suit horsepower goals after original axles failed
In the shops
Driveshaft/Axle Flange Bolt ↗Good Parts· $2.00 USD
Driveshaft or Axle Flange (Yoke) ↗bpnorthwest.com· $37.70 USD
Driveshaft Axle Shaft Bolt and Nut Kit (TR2 to TR6) ↗bpnorthwest.com· $2.39 USD

Body & Trim 1

Fresh sheet metal patch panels
Welded in to repair rust found near the rear half-shaft tunnel area
In the shops
Trunk Floor Sheet Metal, MGA ↗Betaset (France)· €2,961.00 EUR
Left intermediate sheet metal ↗Betaset (France)· €46.00 EUR
Straight Bulkhead Sheet Metal ↗Betaset (France)· €216.32 EUR

Electrical 1

KIA blower motor
Fitted as an upgrade to improve airflow in the factory AC system

Photos

354 pictures collected from the write-up, in the order they were posted, shown from boosted300's RB 240Z. A picture opens larger here, with the way through to the page it is on.

boosted300 · 2017-03-19T18:33:45Z 2this post at boosted300's RB 240Z ↗

boosted300 · 2017-03-19T18:37:13Z 3this post at boosted300's RB 240Z ↗

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How it was done

Starting condition

boosted300 bought the 280Z as a non-running RB25DET swap from a previous builder, having waited nearly a year to take delivery. It looked finished but several details turned out to be improvised or wrong, including mismatched CV axle measurements supplied to the DriveShaft Shop.

Early problems

On early drives a rebuilt CV axle failed, the wheels spun under boost without traction, and a dyno session revealed the existing tune was poor. Paint chipped on the hood and 235-width tyres proved inadequate for the power on hand.

Electrical and AC work

Installing the factory-option air conditioning led to a wiring harness melting in the dash, forcing a rewire from scratch. The AC blower was upgraded using a KIA fan, and the system went through more fitting, a cut dash, and repeated trips to an AC specialist shop to fix a non-working vent flow.

Turbo and cooling upgrades

Working with Doug at FabShop Miami, boosted300 replaced the stock cast manifold with a tubular header, moved to an external wastegate and larger intercooler core from Bell with custom end tanks, and reworked the wastegate flange and piping to fit around the newly added AC condenser.

Chassis repair

While cleaning undercoating, rust was found on the rear of a factory half-shaft tunnel area, prompting cutting out and welding in fresh sheet metal before the car was put back together.

Dyno and tuning

Multiple dyno sessions followed the hardware changes, including a session where fuel pressure problems traced to a restrictive rubber hose were resolved, followed by a more successful pull with fuel pressure holding steady.

Progress so far

The car has been driven to local cars and coffee meets, fitted with a Platinum Racing Products coil pack kit to replace ageing ignition components, and continues to receive small refinements such as an LS-style alternator and coolant system tweaks.

A summary in our own words. The full account, with all its detail, is in the original write-up: read it at boosted300's RB 240Z ↗

Worth knowing

Confirm CV axle measurements directly rather than relying on figures given by a previous owner
Check for hidden restrictions, such as collapsed hose sections, when fuel pressure problems appear on the dyno
Tyres rated for the car's actual power are necessary, as 235-width tyres were not enough for the output being made

An RB25DET-swapped 1978 Datsun 280Z rebuilt for boost and AC

Specs

Parts used

Engine 1

Fuel & Ignition 2

Cooling 3

Gearbox & Drivetrain 1

Body & Trim 1

Electrical 1

Photos

boosted300 · 2017-03-19T18:33:45Z 2this post at boosted300&#039;s RB 240Z ↗

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