72 Ultra Orange - Bucket List Restomod

[72ultraorange]

Quick update… After hours of cutting, welding, and grinding - Finished the fuel cell cage - still need to touch up some of the welds and more grinding to do Also need to drill all the holes for the fasteners.

Designing this in CAD and sending out for plasma cutting would be well worth the time for the next fabrication; but it’s done and it will work! Here was the original design concept — if you missed it: https://www.the510realm.com/viewtopic.p ... 53#p292153

The best part of all - I still have room for speakers and a sub! Oh and my old skool scissor jack!

Some build pictures:

FD01D30D-6EAC-4812-8F77-FCD991CAF62C.jpeg (299.38 KiB) Viewed 2114 times

94CD5707-4CA7-4160-9C73-ACC4A1ED8CBE.jpeg (426.66 KiB) Viewed 2114 times

Test Fitment:

F048E98D-4496-4CBF-B98C-DBDE6E3B612A.jpeg (360.92 KiB) Viewed 2114 times

A980F690-118A-47E3-9F3D-023EF434B40E.jpeg (476.26 KiB) Viewed 2114 times

Tank Installed

D2E1D0A2-074F-4004-817A-54358B7F0883.jpeg (319.27 KiB) Viewed 2114 times

1401EDE7-33AB-4763-9B95-0F1BF96FCCED.jpeg (517.52 KiB) Viewed 2114 times

6EB3C50A-200F-4BA2-809E-5AADAE5BBECC.jpeg (402.61 KiB) Viewed 2114 times

8636CDE1-0919-4469-B38F-308A726E6697.jpeg (481.69 KiB) Viewed 2114 times

5D4E1529-B562-470E-8298-AF3585B29188.jpeg (342.46 KiB) Viewed 2114 times

ED01AE24-4F60-4976-8BA2-46BBA2FAD276.jpeg (397.66 KiB) Viewed 2114 times

[72ultraorange]

Working to get all the turbo air plumbing done when the exhaust is done. Ordered a new 70mm throttle body and installed; needs some shorter bolts for the Greddy intake manifold but now ready to get to exhaust fabricator. Will be sending her out for exhaust fabrication next weekend and it will take 2-3 weeks. Also plan to install ISR MAF and HKS Super Power Flow air intake.

Here’s the S90 throttle body from S90 Racing: https://www.s90racing.com/

FAB1D8B1-21A3-48FF-A007-2764A2604784.jpeg (413.82 KiB) Viewed 2110 times

2451860A-C492-4014-AE8F-2AFA25D93C62.jpeg (430.29 KiB) Viewed 2110 times

[loungin112]

Good looking throttle body. Visited the webpage and my antivirus blocked it, saying "this is a known dangerous webpage..." Oh well. Remind me, is this for an SR or a KA?

"The best part of all - I still have room for speakers and a sub! " Noooooooooooooo!

[72ultraorange]

Good looking throttle body. Visited the webpage and my antivirus blocked it, saying "this is a known dangerous webpage..." Oh well. Remind me, is this for an SR or a KA?

"The best part of all - I still have room for speakers and a sub! " Noooooooooooooo!

Ha - did not get any warnings on that website…
The throttle body is for an SR20DET. I shopped around and did some research on some other SR forums. This particular one is no longer made by S90 Racing but found one online from Malaysia. (P/N: S90-NIS-270). It’s billet and looks like it will hold up. Maybe one day I can actually see if it will work.

[72ultraorange]

Finished welding up the fuel cell cage. Drilled all the holes for mounting cage to car and fuel cell to cage. One more grinding session before going to powder coating.

Hacked in the E-brake with a temporary cable this week to stop having to use blocks every time I roll it out of garage

Delay at exhaust fabrication shop — hoping to get it there this week (TBD)

A few small projects left before paint and body shop
- install AC evaporator and piping through firewall with bulkhead plates (Drill holes; test fitment)
- make bracket to hold 3 MBC/Clutch cylinder remote reservoirs
- finish hydraulic hood lifts and attempt to make hydraulic lifts work for trunk
- make temporary bracket for AC Compressor to ensure Exhaust and IC piping can be plumbed; this will need a custom bracket made to use a modern compressor

It appears that the CX Racing IC will need to be replaced / modified due to the piping interference with the AC condenser and compressor. Planning to have turbo exhaust fabricator rework IC.

Here are some pictures of the fuel cell cage almost ready for PC:

C45EC94A-2E8C-47F1-B853-1C6D7239B4D9.jpeg (437.84 KiB) Viewed 1938 times

9E931CB8-73E3-48C6-91C9-D86BE927FE6B.jpeg (430.99 KiB) Viewed 1938 times

* Didn’t notice the stainless fuel cell frame was not seated when I took these… it fits very well…

64CBB563-3D82-4008-8D7D-034B6165F150.jpeg (422.88 KiB) Viewed 1938 times

D3F63C42-1CDC-4D9D-981F-89751B5755E0.jpeg (443.84 KiB) Viewed 1938 times

A0567286-ADEE-4D23-A7B9-2D73179AD55D.jpeg (455.76 KiB) Viewed 1938 times

[eastbaysolo_73]

Great job bud

[72ultraorange]

Great job bud

Thanks man! Glad to get this one finalized and move on!

[ctdavid73510]

Nice Build. What are you running for wheels? I'm interested in the size and offset as well.

[72ultraorange]

Nice Build. What are you running for wheels? I'm interested in the size and offset as well.

Hey that’s a great question. Right now, it has the original 205/50R15 tires and Rota RB wheels that came with it. Luckily they have worked for the mockup. Before I tear it back down for paint and body work, plan to get all of the offset measurements determined. For the wheels, I plan to go with either Rota RKRs, Volk TE37, Atara Racing Pisang, or RS Watanabe wheels (TBD)…

I like the stance with the 15’s on it; but will work to get as much width as possible in front and back for extra traction. Once we have all the measurements and fitments determined I plan to have the paint and body shop modify the fenders to adapt to my flare kit from Carbon Signal Automotive. Still don’t know exactly what wheels will be going with. Really not sure on offsets yet… rear probably needs positive offset to clear inner fender; front might need negative offset. Getting wider 15’s on it will be a fun challenge.

A lot of great tire / wheel info here: http://www.the510realm.com/viewtopic.php?t=26740

Here’s a picture of the body kit I have to go on it and a look I am trying to replicate. This is a really nice 510:

B062C7FA-A667-48C9-BB36-DD2208D82318.jpeg (406.13 KiB) Viewed 1765 times

[icehouse]

Hopefully you go lower. 510's look so bad with fender gap.

Also Why the big throttle body? S13 SR was 60mm S14/15 was 50mm The smaller throttle body made it way easier to control. I once built some intake manifolds with the Q45 90mm throttle body. Such a bad idea. Zero control. Hopefully 70mm isn't to much.

[72ultraorange]

Hopefully you go lower. 510's look so bad with fender gap.

Also Why the big throttle body? S13 SR was 60mm S14/15 was 50mm The smaller throttle body made it way easier to control. I once built some intake manifolds with the Q45 90mm throttle body. Such a bad idea. Zero control. Hopefully 70mm isn't to much.

Hey Ice, certainly have some fitment work to do on wheels and tires… I do plan to keep the 15s on it; before the alignment; the oil pan was ~4” off the ground; fun times ahead.

On the throttle body — the 70mm size was all that was available from S90 Racing and was looking for an upgraded billet TB. We have a long way to go before we can check it out; will keep this in mind when we get to that part of the build. Will hang on to original TB until we get past that. Appreciate your feedback!

[72ultraorange]

Temporarily fitted in the Vintage Air Evaporator and bulkheads through firewall for the AC and heater plumbing. Will need to modify the brackets / strapping to work with the 510 dash frame for final installation. Otherwise, the real Gen II Super evaporator unit fits as I have it mounted. Will have local installer complete all the plumbing once we get to that point. 45 degree, 90 degree, and straight through bulkhead beadlock fittings may be adjusted for additional clearance. I picked the best one’s from the stack the shop gave me.

Working with a local fabricator to have an AC compressor bracket fabricated for the SR20 installation. This has turned out to be challenging as the S14 OE compressor bracket doesn’t line up with any modern compressors. I elected to go with the Sanden SD-7B10 with side ports to ensure clearing the turbo plumbing and there are no brackets that will work for it.

Bulkhead adapters:
Vintage Air Dual Bulkhead part numbers:
389602 for AC lines (#6 and #10)
389803 for heater lines (#10)

Right Side clearance prior to bulkhead installation

F0B7A5C5-A957-46A0-9EF3-FC854A880BF9.jpeg (229.41 KiB) Viewed 1492 times

Unit Installed

A3221C00-92EE-430B-9C08-9D60E0ECE283.jpeg (384.57 KiB) Viewed 1492 times

9BDECE6D-D742-4871-A742-6380172B936B.jpeg (333.52 KiB) Viewed 1492 times

A562EA4F-3F05-42B3-A562-A524F619FD87.jpeg (477.92 KiB) Viewed 1492 times

Bulkhead Locations (Upper - AC behind strut tower, Lower - Heater)

530082B0-4774-41A1-9409-BAF26F6D08D5.jpeg (439.62 KiB) Viewed 1492 times

FAD0A584-7229-45D5-924B-61241800FB21.jpeg (496.55 KiB) Viewed 1492 times

[72ultraorange]

Hopefully you go lower. 510's look so bad with fender gap.

Also Why the big throttle body? S13 SR was 60mm S14/15 was 50mm The smaller throttle body made it way easier to control. I once built some intake manifolds with the Q45 90mm throttle body. Such a bad idea. Zero control. Hopefully 70mm isn't to much.

Hey Ice, certainly have some fitment work to do on wheels and tires… I do plan to keep the 15s on it; before the alignment; the oil pan was ~4” off the ground; fun times ahead.

On the throttle body — the 70mm size was all that was available from S90 Racing and was looking for an upgraded billet TB. We have a long way to go before we can check it out; will keep this in mind when we get to that part of the build. Will hang on to original TB until we get past that. Appreciate your feedback!

Ice, here are a couple of other 510s that have a great stance and are lowered. We’ll try to get to this . Wheel fitment and fender clearance will be critical. If anyone has good place to start with offsets and max wheel sizes for 15’s (15x8.5 or 15x9) let me know your thoughts. Thanks!

Both Awesome 510s’:

http://www.speedhunters.com/2016/01/fly ... -bluebird/

https://stickydiljoe.com/2012/12/04/exc ... et-dec-12/

[icehouse]

Those look nice. We have 245/40R15 on our racecar for the next race. We had 225's before. Excited for the added grip. Looks way better with wider tires too. The flares we run are the metal guys off ebay.

[72ultraorange]

Quick update on progress:

- Still no luck getting exhaust fabricated; contacted another shop - they said maybe this week

- Custom drive shaft from https://driveshaftshop.com/ came in . Will test fit later on a lift!

- Initial scans for AC compressor and SR20 compressor bracket complete - having custom bracket designed for Sanden SD-7B10 compressor

- Finished the hood gas lift installs following Stu’s installation notes with the longer gas struts; reinstalled hood for test fit.
THANKS Stu for your detailed build posts!! http://www.the510realm.com/viewtopic.ph ... 4&p=279994
I had followed the Dime Quarterly article but the gas strut ball ends were interfering with the hinge based on where I drilled holes. The longer gas struts worked much better.

Some pictures:

Drive Shaft:

62573A51-125B-4004-B4EB-51A3CAF1EE22.jpeg (56.59 KiB) Viewed 1035 times

Initial scans of SR20 AC Compressor bracket and Sanden SD-7B10 compressor for custom bracket design:

B4170B88-AEE2-4D16-808D-48FB1B97AB9C.jpeg (273.37 KiB) Viewed 1035 times

01FBAA20-6321-40AE-B959-3BFE7FE53DE6.jpeg (220.73 KiB) Viewed 1035 times

Hood Gas Strut Install - Longer 9416K12 (8.15” 80 lb force) from McMaster-Carr:

2474A901-2752-4C3D-BA6B-2B21C2713EB0.jpeg (377.2 KiB) Viewed 1035 times

DCBD3D31-B683-4A06-9AAB-01F79214B70C.jpeg (359.32 KiB) Viewed 1035 times

44FB214E-F66E-49F3-948C-019BDDE2AA59.jpeg (495.97 KiB) Viewed 1035 times

E2CEBA5E-7BF6-45C7-9F96-A38D34BCED08.jpeg (522.73 KiB) Viewed 1035 times