72 Ultra Orange - Bucket List Restomod

[72ultraorange]

Not sure I’ve ever seen a diffuser like that on a 510, will be interesting to see how it comes out.

ME EITHER

[72ultraorange]

Can’t wait to see the finished product!

Thanks...I can't wait to see it either. Shop said it would be there 2 months - media blasting tomorrow!

[72ultraorange]

Finally - after 3 years -- she is at the Paint and Body Shop. Never thought I would get here...will be there a minimum of 2 months.

No time to relax - Next up - going to work on finalizing the following:

1) Complete Dash setup
- Complete Dash Gauge selections, purchase and install
- Complete wiring diagram(s) starting with the American Autowire 22 Highway universal kit
- Complete controller switches / aux electronics / stereo mock in / layout
- Powder Coat Dash and assemble gauges
2) Rebuild Transmission / Review Rear Diff again for proper gear setup
3) Rework boots on rear axles. Removing the rear crossmember with them installed cut the seals where they contacted the retainer
4) Select the ECU for the SR20 and finalize the Wiring Specialties wiring harness design and order
5) Research interior / upholstery shops that can recover back seat, carpets, interior
6) Complete fabrication and grinding on fuel cell cage, powder coat
7) Assemble Fuel Cell
8 ) Powder coat remaining parts
9) Research building a custom console

When she comes back, the suspension and drive train will be installed and returned to a roller! My goal - ready to run by mid summer! however; not taking bets at this point please

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[loungin112]

Looking forward to seeing how it all turns out. I can see what you are going for. The hope for my build feels similar. But, I'm such a far ways away at this point. Heck...I can't even bring myself to put my new brakes and suspension on for fear of not being able to drive this summer.

[72ultraorange]

The paint and body shop has gotten to work right away and completed the media blasting and initial primer coat. They are shaving the engine bay and starting on the metal! It is great to see this progress…taken a long time to get here… and for anyone reading this; patience is absolutely required when embarking on a 510 build… and I thought I would be done this time last year! It took months waiting to get into the fabrication shop for the exhaust and months more to get into the body shop.

Update (Post media blasting): The body shop identified a few areas of rust for repair during the media blasting:
- Pin holes in drain cowl on both sides. - they plan to cut out the metal that holds the 2 vents in place on either side, repair it, and then weld those back.
- Driver’s side floor pan - minor repair
- Left trunk floor pan - minor repair
- Front left fender - lower corner - minor repair
- Rear left door — had significant bondo and holes drilled to pull out dents in door in past… New skin to be put on — from Futofab.com
Car is in good shape otherwise.

Here’s the work ongoing: FUN TIMES AHEAD

Was mounted on a rotisserie to complete bead blasting and primer coat:

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Bead blasted and primed for metal working:

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Back on the dolly working on metal / shaving engine bay:

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[72ultraorange]

Few more weeks at the body shop - hope to get some more pictures this week. The diffuser was fabricated from aluminum and will be mounted to a new trunk floor plan.

Here’s a few pictures of the progress on the rear diffuser at the body shop:

Inside Trunk:

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Under trunk:

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Partial Fabrication of Aluminum Diffuser:

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[72ultraorange]

Have been working through the fuel cell assembly and have it almost complete. The FCST and pumps are installed along with the fuel level sender. Today’s big news - the SR20DET arrived back from Mazworx after a 5 month rebuild. Glad to get the heart of my build back!

This past weekend I also gained a new appreciation for being on the track. Ran 4 -25 minute sessions in an HPDE event 2.5 mile track. I was blown off the track by much more nimble, smaller, lower powered cars (with drivers much better than me) and even though I could beat them on the straights, this one event burnt thru most of my front rotors. It was a blast BUT now I understand the extreme dynamics of this particular track and things I need to think about in my build - and its time to make sure the 510 can handle this punishment. Hoping the suspension, BBK, drive train and other systems will help get this 510 to be a competitor — and if not have a lot of fun! Brakes and tires along with suspension dynamics will be some focus areas for me to get right.

Here’s some pictures of the fuel cell internals and the rebuilt engine — we MUST get this on the track this year!

Fuel Cell / Surge Tank / Pump Assembly - (The surge tank housing is not pictured in this photo) - primary and backup pump on right sit inside the surge tank. Lift pump on lower left.

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Surge tank (pre assembly)

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Fuel Cell with FCST installed:

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Engine Pictures:

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[Stu]

Looking great. Are the diffuser ribs solid or bent/welded sheet?

Stu

[72ultraorange]

Looking great. Are the diffuser ribs solid or bent/welded sheet?

Stu

Hey Stu,Thanks! Regarding the diffuser, there is one large plate that matches the trunk pan dimensions and will be bolted through that pan. Each rib was cut using a CNC plasma table out of 8” bar stock. This is all 3/8” (0.375) 6061 Aluminum. I believe they are going to bolt each fin thru the main plate to attach; but we also discussed TIG welding this together. I will know more this week on what has been done. It will be powdercoated before install. Also has horizontal winglets that are being added to outside fins. More pictures soon.

[72ultraorange]

Body shop is finalizing the diffuser and finished tweaking the transmission tunnel. The Diffuser is being partially TIG welded and bolted together. 2 fins are installed to attach the winglets. 1/2 of the car is blocked and sanded…

Some pictures of the diffuser progress:

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Transmission Tunnel finished:

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[72ultraorange]

Not much going on at body shop - got test paint strip (HEMI Orange!) - looks great and the diffuser is being finalized. Still weeks away from being done —it’s a busy shop. Here’s the diffuser - final assembly in progress. Once done, it will be taken off and powder coated.

Happy with how it is turning out.

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[72ultraorange]

Update - She's been in the body shop for 13 weeks.

Some notes from this week:
Worked through the fender flare installation with the shop - we will be cutting the fender lips out to accommodate different size tires (TBD). Front fenders are easy compared to rear. Rear will require some welding to "heal" the 2 sheets of metal that are in the top of the rear wheel wells... and we will not be cutting into the door areas since this is a 4 door.

Other Metal work to be completed:
- Repair firewall pinch weld
- Repair / straighten rocker panel pinch welds
- Install trunk hydraulic lift / pivot points in trunk
- Cut all 4 fenders for flares / "heal" the back wheel wells
- Drill holes in roof for "sharkfin" type antenna
- Cut front fender openings for JDM style fender mounted mirrors
- Drill hood / radiator core support for hood latch pins

Paint in 3-4 weeks is what I am expecting. Here is the paint sample ... will get better pictures after we get it on the car

Hemi Orange (Paint Code PLC) with minimal flakes.

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[72ultraorange]

The body shop is installing the FRP body kit which consists of fender flares/overriders, front splitter, and rear spoiler. For final assembly, these will be attached with bolts and gunmetal grey fasteners from Zspec design: https://zspecdesign.com

Body Kit from: CarbonSignal Automotive: https://www.facebook.com/carbonsignal1/

Here are a few pictures of the body kit installation:

Rear wheel wells - metal cutting / welding to heal the seams back (will get additional pictures of this soon):

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Rear fender flares/overriders for 4 door:

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Front Splitter:

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[RONSLYCHUK]

The body shop is doing a very good job,looks great.

[72ultraorange]

Update from body shop; happy with progress over past 2 weeks:
- body kit (minus trunk spoiler) completed
- the fender mirrors have been installed
- roof mount antenna installed
- assembly mock up of rear diffuser is complete - it will be taken off next week to get to powder coating

Metal Work remaining prior to paint:
- final welding of wheel wells
- body kit is installed with temporary bolts — holes to be drilled and rivnuts installed
- trunk mounts for hydraulic lifts to be installed
- hood latch pins
- final body prep

A few updated pictures from the shop

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Rear diffuser (2 fins not installed in these photos)

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Roof Mount Antenna Installed:

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Few more of the car:

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