Revolutionizing the Classic: The All-Aluminum Datsun 240Z Transformation
The iconic Datsun 240Z is known for its classic design, but like many cars of its time, it faced issues with rust. This particular 240Z has tackled that problem head-on by replacing most of its body with aluminum. The owner, Topher Pine, collaborated with Japanese Z specialist Star Road to make this vision a reality. The car is constructed using 5000-series aluminum, with many body panels stamped at the same facility as the new Lexus LFA and Toyota prototypes.
Unlike most production cars that use a mix of steel, aluminum, and plastics, this 240Z has gone nearly all-aluminum, reducing its weight by approximately 70 kilograms. The use of magnesium in certain components enhances corrosion resistance, and the aluminum doors are claimed to be 1.6 times stronger than the original steel ones. While other vehicles like the Tesla Cybertruck and DeLorean DMC-12 opt for all-stainless-steel construction or carbon fiber for ultra-lightweight builds, the aluminum construction of this 240Z offers a practical alternative that is lighter than steel and more cost-effective than carbon fiber.
Despite the extensive use of aluminum, some steel components remain in the A-pillars, headlight housings, rocker panels, rear roll pan, and door reinforcements. The car is powered by a turbocharged 2.5-liter RB25 inline-six engine, replacing the original L24. Pine aims for an output of 400 to 450 horsepower with this engine. The build also features upgrades like a Star Road big brake kit, suspension components, seats, harnesses, and a steering wheel from Number 7 Racing. Pine is still deciding on the final paint finish but plans to maintain the unique all-aluminum look of the car.
The all-aluminum 240Z was showcased at SEMA 2025, and Pine hinted at making the aluminum body panels available after the Tokyo Auto Salon. This move coincides with the debut of Toyota's new flagship sports car, the Toyota GR GT. The collaboration between Pine and Star Road has resulted in a remarkable transformation of the classic Datsun 240Z, offering a blend of modern materials and performance upgrades that pay homage to the car's heritage.