1972 Nissan 240

The Story

Meet the Builder — Sam Mahdavi

Sam Mahdavi, host of the nationally syndicated Sam's Garage, has spent his career around cars, builders, and the people who make the automotive world special.

Sam brings more than mechanical knowledge to a build. He understands that the best vehicles usually have a story behind them.

As a builder and partner in My Legacy Car Show, Sam will help us uncover those stories, meet the people behind the vehicles, and bring some truly special Legacy Builds to life.

Because sometimes the most important part of a build isn't what's under the hood.

It's why the vehicle matters in the first place.

Ferrari 250 GTO Replica

This is our take on one of the most famous Ferraris ever built, the legendary 250 GTO.

The car is built on a 1972 Datsun 240Z chassis that we completely upgraded, including the front and rear suspension and rear differential.

Under the hood, we built a 347-cubic-inch Ford small block on the set of Sam's Garage and paired it with the same five-speed transmission we used in the Thunderbird. We added an eight-stack fuel injection system, relocated the coil packs, and eliminated the distributor to give the engine a more modern setup while keeping that incredible old-school look.

Inside, we created a custom Ferrari-inspired dashboard with new seats, interior, custom gauges, and Vintage Air conditioning. We also added Wilwood brake upgrades and new wheels.

Our friends at STATE Collision Center finished it off with a complete repaint.

Doug has had this car in his collection for about 30 years, and it's believed to be one of only four like it in the country.

This isn't a factory Ferrari. It's a completely custom-built tribute that we created on the TV show, combining the unmistakable look of the 250 GTO with American V8 power.

You won't see many builds like this one.

Milestones

Photos

Restoration Timeline

Chapter 1 • Milestone 1: More Than Just a Car
Chapter 1 • Milestone 2: Upgrading the Front Suspension
Chapter 1 • Milestone 3: More Power Needs More Brakes
Chapter 1 • Milestone 4: Dialing In the Suspension
Chapter 1 • Milestone 5: Building the 347 Stroker
Chapter 1 • Milestone 6: The 347 Comes Together
Chapter 1 • Milestone 7: Mocking Up the New Powerplant
Chapter 1 • Milestone 8: Upgrading the Rear Suspension
Chapter 1 • Milestone 9: Rebuilding the Rear Suspension
Chapter 1 • Milestone 10: Bringing the Rear Brakes Up to Speed
Chapter 1 • Milestone 11: Getting the Brake System Balanced
Chapter 1 • Milestone 12: A New Interior Takes Shape
Chapter 1 • Milestone 13: Insulating the GTO
The story continues

Build Timeline

Chapter 1 • Milestone 1: More Than Just a Car

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Chapter 1 • Milestone 1: More Than Just a Car

This project starts with something you can’t buy from a parts catalog.

Thirty years of history.

The 1972 Nissan-based Alpha 1 250 GTO has been with its owner for three decades. Now it’s getting a new chapter.

The goal isn’t to change what makes the car special. It’s to make it perform as good as it looks.

The plan includes a 302 cubic inch engine built for around 500 horsepower, major brake upgrades with four piston calipers, improved suspension, chassis strengthening, and eventually a complete reassembly and interior.

But buried inside the mechanical details is the part of the story we think deserves to be preserved:

The engine belonged to the owner’s brother.

That changes what this build is about.

It’s not simply an engine swap. A piece of family history is becoming part of a car the owner has already spent 30 years with.

That’s exactly why we created Legacy Builds.

Horsepower matters. Parts matter. The finished car matters.

But sometimes the most valuable part of a build is the story you would never know just by looking at it.

And now this one won’t get lost.

Chapter 1 • Milestone 2: Upgrading the Front Suspension

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Chapter 1 • Milestone 2: Upgrading the Front Suspension

The Alpha 1 GTO project moves into the front suspension.

Before the upgrades can begin, the old setup has to come apart. That starts with removing the classic Dayton wire wheels and knockoffs.

There’s a small detail here that could easily get forgotten over the years: these wheels use both right hand and left hand threads, depending on the side of the car.

Tech Tip

When servicing knockoff wheels, apply anti seize to the threads. It can make life a whole lot easier the next time those wheels need to come off.

It’s exactly the kind of little detail worth documenting in the vehicle’s permanent build history.

Next up: getting deeper into the Alpha 1’s new front suspension.

Chapter 1 • Milestone 3: More Power Needs More Brakes

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Chapter 1 • Milestone 3: More Power Needs More Brakes

The Alpha 1 GTO is getting a serious horsepower increase, which means the braking system needs to keep up.

The team takes a closer look at the original brake setup and why it’s no longer enough for what this car is becoming.

The existing rotors are non vented, limiting their ability to manage heat during harder braking.

They also discuss an important detail about drilled rotors. They may look great, but under repeated heavy braking, the drilled holes can become stress points where cracks can develop.

What We Learned

Adding horsepower is only part of building a better car.

If you're going to make it faster, you better make sure you can stop it.

This milestone begins the Alpha 1’s braking transformation and lays the groundwork for a system designed around the performance this car is about to have.

Chapter 1 • Milestone 4: Dialing In the Suspension

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Chapter 1 • Milestone 4: Dialing In the Suspension

The Alpha 1 GTO continues its transformation with a major upgrade to the front suspension.

The factory front struts are being replaced with an adjustable coilover system.

With the engine swap and other changes being made to the car, the original weight balance is changing too. The new coilovers give the team the ability to tune the suspension around the car they’re actually building, rather than the car that left the factory.

Why Coilovers?

The new setup allows them to adjust:

Spring rates

Ride height

Damping

Overall handling characteristics

That means once the Alpha 1 is back on the road, the suspension can be dialed in to help the car stay planted and perform through the corners.

More horsepower is great. Making the entire car work together is what makes a great build.

Chapter 1 • Milestone 5: Building the 347 Stroker

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Chapter 1 • Milestone 5: Building the 347 Stroker

The Alpha 1 GTO project now turns to one of the most important parts of the build: the engine.

The team is assembling a 347 stroker based on the Ford 302, giving the car the powerplant that will eventually transform how it performs.

Building a stroker isn't simply a matter of installing bigger parts. The increased stroke creates tighter clearances inside the engine. The block has to be properly machined and notched so the pistons and connecting rods have the clearance they need.

During assembly, attention shifts to protecting those new components. Assembly lube is applied generously to the crankshaft so critical surfaces are protected during initial assembly and startup.

What We Learned

More horsepower starts with getting the small details right.

Clearances, machining, lubrication, and careful assembly may never be visible once the engine is installed, but they're part of the story worth documenting.

And this engine has an even bigger story behind it: it's the engine that belonged to the owner's brother.

That's exactly the kind of detail My Steward Registry is meant to preserve. Years from now, someone shouldn't just know there's a 347 stroker under the hood.

They should know why that engine matters.

Chapter 1 • Milestone 6: The 347 Comes Together

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Chapter 1 • Milestone 6: The 347 Comes Together

The 347 stroker for the Alpha 1 GTO continues to take shape as the team moves from the bottom end into the next major stage of engine assembly.

The cylinder heads are installed onto the block and carefully torqued to factory specifications. From there, work moves to the valvetrain and timing components, bringing the engine another big step closer to being ready for the car.

This is where all the individual pieces we've been documenting begin turning into a complete engine.

What We Learned

Building an engine isn't just about having the right performance parts. How those parts are assembled matters just as much.

Proper torque specifications, correct installation, and careful attention to the valvetrain and timing system all become part of the documented history of this engine.

For this particular build, that documentation means even more. This isn't simply a 347 being assembled for more horsepower.

It's the owner's brother's engine being given another chapter.

Chapter 1 • Milestone 7: Mocking Up the New Powerplant

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Chapter 1 • Milestone 7: Mocking Up the New Powerplant

With the 347 stroker coming together, the next step is making sure it actually fits the Alpha 1 GTO.

The team begins the mockup process, replacing the factory engine with the 347 stroked Ford Windsor pushrod engine.

This isn't the final installation. The goal is to temporarily position everything so they can check clearances, determine what needs to be moved or modified, and solve those problems before the finished engine goes in.

The swap should completely change the personality of the car. They're gaining significant horsepower and torque while also reducing weight.

What We Learned

Mockup is where the plan meets the actual car.

Something that looks right on paper doesn't necessarily fit once the engine is sitting between the frame rails. Finding those problems now can prevent expensive mistakes later.

And it's another important part of the vehicle's history worth documenting.

Not just what engine ended up in the car, but how they made it work.

Chapter 1 • Milestone 8: Upgrading the Rear Suspension

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Chapter 1 • Milestone 8: Upgrading the Rear Suspension

The Alpha 1 GTO project moves to the rear suspension, where the factory control arms are being replaced with fully adjustable billet aluminum arms.

The new setup gives the team much more control over the suspension geometry and allows them to properly dial in the car as the rest of the build comes together.

But getting the old suspension apart presents its own challenge.

Years of age, rust, and corrosion can leave suspension bolts and pins completely seized. The team shares a simple but important trick: when driving out a stubborn pin or bolt, leave the nut threaded on the end. This protects the threads from being damaged by the hammer.

What We Learned

Upgrading an old car isn't always about installing the new parts.

Sometimes the hardest part is getting 50-year-old parts off without destroying something in the process.

The adjustable rear suspension is another important piece of the bigger goal for this Alpha 1 GTO: more power is coming, but the chassis, brakes, and suspension all need to be ready to handle it.

Chapter 1 • Milestone 9: Rebuilding the Rear Suspension

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Chapter 1 • Milestone 9: Rebuilding the Rear Suspension

The Alpha 1 GTO project continues with the team turning their attention to the rest of the rear suspension.

They remove the upper strut tower covers to gain access to the rear assemblies and continue rebuilding the suspension with new components.

What They’re Doing

The rear receives new coilover springs to match the upgraded setup already installed in the front. This brings the front and rear suspension together as one more complete performance package.

They also replace the rear wheel bearings and seals. At roughly 41 years old, these are exactly the kinds of parts that make sense to replace while everything is already apart.

What We Learned

A good build isn't only about adding performance parts.

Sometimes the smartest upgrades are the ones nobody sees.

New bearings, seals, and suspension components help make sure the foundation of the car is ready for the additional horsepower, braking, and handling improvements being added throughout the build.

The goal isn't just more performance. It's making the whole car ready for it.

Chapter 1 • Milestone 10: Bringing the Rear Brakes Up to Speed

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Chapter 1 • Milestone 10: Bringing the Rear Brakes Up to Speed

With more power and better suspension going into the Alpha 1 GTO, the factory rear drum brakes are no longer a good match for what this car is becoming.

The team converts the rear to a Wilwood four piston disc brake setup, using larger cross drilled and vented rotors designed to better manage the heat created during harder driving and track use.

The conversion also includes a separate emergency brake caliper, allowing the car to retain a functional parking brake while gaining the performance advantages of the new rear disc setup.

What We Learned

A performance build has to work as a complete system.

Adding horsepower is only part of the equation. The brakes, suspension, tires, and chassis all need to be capable of controlling that power.

For this 30 year ownership story, it's another important step in turning the Alpha 1 GTO into the car its owner always wanted it to be.

More power means you better have more stopping power.

Chapter 1 • Milestone 11: Getting the Brake System Balanced

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Chapter 1 • Milestone 11: Getting the Brake System Balanced

The Alpha 1 GTO brake upgrade continues with work on the heart of the system.

The original master cylinder is replaced with a new direct replacement unit. The team also installs a new proportioning valve, which helps maintain the proper brake bias between the front and rear.

That becomes especially important now that the GTO has upgraded braking components at both ends of the car.

What We Learned

Upgrading brakes isn't just about bigger rotors and more powerful calipers. The entire system has to work together.

The proportioning valve helps balance braking force between the front and rear, while the new master cylinder gives the system a fresh foundation.

There's also a simple shop lesson here: use the right tool for the job. A line wrench helps prevent damage to the brake fittings while they're being removed and installed.

Another small piece of the build, but an important one as the Alpha 1 GTO gets closer to becoming a complete, properly balanced performance car.

Chapter 1 • Milestone 12: A New Interior Takes Shape

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Chapter 1 • Milestone 12: A New Interior Takes Shape

With the Alpha 1 GTO’s engine, brakes, and suspension being transformed, attention now turns to the inside of the car.

Jay Stitch joins Doug and the team as they begin removing the existing interior and preparing the GTO for a complete reupholstery.

The goal is to create an interior that feels like it belongs with the rest of the build while still respecting the unique character of the car.

What We Learned

A complete build isn't just about horsepower and handling.

The interior is where the owner actually experiences all that work.

Stripping everything out also gives the team a chance to start fresh, inspect what’s underneath, and plan the new interior before upholstery begins.

After upgrading how the Alpha 1 GTO runs, handles, and stops, it's time to upgrade the place where the owner gets to enjoy it.

Chapter 1 • Milestone 13: Insulating the GTO

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Chapter 1 • Milestone 13: Insulating the GTO

The Alpha 1 GTO is getting closer to the finish line.

After spending roughly 30 years with its owner, the car has gone through major upgrades to the engine, brakes, suspension, and interior. Now the team is working on some of the details that will make the finished car more enjoyable on the street and as it gets ready for the racetrack.

Lizard Skin Insulation

The team applies Lizard Skin insulation to the interior as part of the preparation before everything starts going back together.

It’s one of those steps that won't necessarily be visible when the project is finished, but it becomes part of the documented story of how the car was built.

More Than Just the Car

Something else comes through in this milestone: the relationship between the owner and the people helping bring his vision together.

His engineering background and mechanical knowledge have played a big role throughout the project. After three decades with this car, he's not simply having someone rebuild it. He's actively involved in creating what it becomes next.