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Datsun 240Z rally car restoration

King of the RAC

It’s more than a restoration: it’s a detective story! Here’s how an extraordinary works Z was made new again

Datsun 240Z rally car

Datsun 240Z rally car

 
Attention to detail is everywhere, showing that the factory really thought about the task it was sending the car to do
Looks like a model in our studio pictures, doesn’t it? This ex-works rally 240Z is millimetre-perfect, precisely as it was when the factory brought it to England to contest the wintry 1971 RAC Rally; a distillation of the best the factory could build. But 12 years ago it was pulled from a shed…

Owner Kevin Bristow has spent the past decade restoring the Datsun and, when the easiest option would have been to use lots of new parts, he’s kept the real thing – nearly all of it in a painstaking operation combining forensics and automotive microsurgery, to retain as much of the original car as possible. ‘There was enough of it left that I knew what I wanted,’ he says, at the end of an enlightening ten-year journey.

Between 1970 and ’72, Datsun’s racing department built teams of very special cars for international rallying and made its name with success on the tough East African Safaris. This is one of three machines built in September ’71 for the RAC in November, based on lightweight shells by the racing department, using lightweight pressings from the Z432R but featuring double-thickness chassis rails and outer sills, partly to support the external jacking points. Bonnet, doors and tailgate are in GRP, with Plexiglas windows, and plenty of other parts are unique to the year.

It was the only one of the three team cars to finish and after the rally was left in the UK and sold to A&B Motors in Manchester, to be used as a promo tool to sell more Zs. ‘The dealer paid the VAT and taxed it,’ says Bristow. ‘It was a perfect time to push the Safari win. The idea was that the car would arrive on a transporter with the right names on it, they would take people up the road and frighten the shit out of them, and then sell them a standard model.’

UK registered in 1972 when the carnet ran out, and in different hands from 1973, the 240Z did a handful of rallies with various owners until being put away in a shed in Bishop Auckland in about 1976. It stayed there until Kevin got wind of it and bought it in 1995.

‘I’ve begun to realise how special the 1971 cars were,’ says Bristow, a workshop owner and previous British Historic Stage Rally Champion in his other Z. ‘It’s the most interesting of the models, with the most differences from standard – plastic bonnet, hatch and doors, which they weren’t allowed to have the following year. I’ve learned so much over the past decade and met so many people – including Rauno Aaltonen. Z rally cars were built in batches of three to 10 at a time, from bodyshells made at the Hiratsuka Nissan Shatai body factory, and prepped at the Oppama works competition department, with some engines built at the Omori factory, now Nismo (Nissan Motorsport) HQ.’

These early shells are actually 432R Japanese-market units (the Z wasn’t being sold in the UK at the time) with a provision for a passenger footbrace and to move the seats forward – only for Japan. Under the dash is a big ‘R’, for the racing department. The roof and rear quarters are made out of thinner steel, with thicker chassis rails and sills, but there’s no seam welding.

The suspension struts are thicker, with the ride height increased by extending the tubes and rewelding the spring platforms 10mm higher, putting it at the same height as a Safari car. Monte cars ran lower, with a thinner sumpguard than this ‘rough road’ car’s massive 10mm-thick alloy item, which sits on its own subframe. The steering arms are shorter to quicken response. The 7x14 Kobe Seiko mags are unique to the rally cars, shod with tall Dunlop PW81s of the original type, size and pattern, ‘…found under a guy’s bench in Leeds’. The brakes are President-derived but with a wider caliper to fit over the vented disc, and the servo is a licence-built Bendix.

Attention to detail is everywhere, showing that the factory really thought about the task it was sending the car to do. The headlamps are modified to allow them to be removed from the front, rather than the long-winded process of getting them out from behind the cowls. On Monte cars, Perspex covers were fitted to avoid the sugarscoops filling with snow during ‘offs’ into snowbanks and depriving the crew of illumination. The front struts are further modified to take a cable drive from each front hub, one for each Halda to average out corners – wheelspin makes driving from the transmission pointless.

Twin wiring looms, the second one running essentials only, could be switched over in minutes in case of a failure. Inside, there’s a combined water-temp/oil-temp gauge, so there’s no oil-pressure gauge. Datsun was convinced of the strength of its engineering, and instead fitted an oil light where the handbrake light used to be, housed in the speedo.

Luckily many of these features remained in Kevin’s car, but some had to be painstakingly researched, tracked down or replicated. ‘I had the paint spectragraphed from the underside of one of the toolbox lids to get just the right colour,’ he explains, admitting that his painter took a bit of persuasion to leave the red unmopped to replicate the factory finish. ‘The exhaust megaphones are short versions of the racing manifolds, scaled up from pictures and from what I had left. The internal reinforcement is to stop them getting crushed if backed into a verge – and maybe also to retain Brillo pads long enough to pass noise tests. It was beautifully TIG-welded up with integral skids by Good Fabrications.’

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Datsun 240Z rally car
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Datsun 240Z rally car
  Datsun 240Z rally car
Continued



Other unique features include a larger R200 diff as used on the later 260Z: ‘Much bigger than on the road cars and not in production until 1974, but how were scrutineers to know? It’s got the LSD and pipes for the diff cooler – they were obviously cheating, but who didn’t on rallies…? They’d all gone out in 1970 with diff failure.’ The dampers are original: ‘I took them to Bilstein and now I know the bump and rebound rates… but I’m not telling anyone.’

The motor remains a 2.4 with standard bore and stroke and ‘quite mild’ rally cam, but a special crank and rods and E30 head. The block – still with ‘R4’ painted on the side – is notched to clear the big valves and uses compression rings instead of a normal gasket: ‘This was for servicing on rallies, where they could survive the head being taken off three or four times.’ The alternator – from a commercial, and internally regulated – is from Old Woking Service Station, which hosted the works cars all those years ago when they were in the UK.

The easiest way to have rebuilt the car would have been simply to reshell it. But that would have lost the most important part of its originality, so Bristow let in new sections of metal where necessary, mostly in the rear wheelarches and some of the tricky toolbox area behind the seats. Great debate was had over whether to iron out all of the body wrinkles acquired on the ’71 RAC. In the end he did, so the car is presented as it started, rather than finished, the event. But the left tail-light still bears the legend ‘Aaltonen’ crayoned on its back, as it came from that car’s service pack after Edgar Herrmann creased the rear corner in a burst of over-enthusiasm: ‘Finding that early on was a real boost.’

Finding all the detail parts to complete the car with total accuracy was the biggest challenge, and the search took Kevin and his friends all over the world. Z guru Alan Thomas even found two of the spotlights – actually 130-watt aircraft landing lights – through contacts in Japan. The seats were retrimmed in the correct covering by Newtrim of Horspath, and Kevin himself hand-painted the crew names; if the typography is a bit uneven, it’s meant to be, as it’s an exact copy of the original. To achieve the authentic navigator’s map pocket, he shaped a wooden buck and moulded the replacement around it from glassfibre.

Almost 40 years after it first came here, this car is perfect again. As a comment on a Z club website says: ‘This is the car that the factory built – from the sheetmetal up; this is the car that those men at Hiratsuka, Oppama and Omori built, fettled and sent on its way to Europe. This is the car that Herrmann and Hans Schuller drove, in that legendary “From Harrogate” year. Kevin has not thrown out the baby with the bath water – he’s kept the lightning in the bottle.’

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