Not much has happened recently, but I'll be back onto it next week. What little time I got to spend on it was getting the S15 crossmember up to the 510 rails and get the engine located in the bay. The front crossmember looked like it was going to be a rediculously easy swap. With the engine in the right spot in the bay, it puts the crossmember so close to the 510 standard spot it's unbelievable and the strut tower positioning, although too far inboard is almost perfect longditudinally. But this is where the good news stops. With it all in position, the only thing that is in the wrong spot is the hub center, they sit about 50mm too far forward.
Possible solutions include, move the crossmember back and move the engine forward on the crossmember. This is a relatively easy option, and given there are no foul-ups with the steering rack clearance, it's a very conceivable option. Alternatively, since we need to convert it from LHD to RHD, I plan on using the S15 firewall section to do this, enabelling the use of S15 pedals, brake master and booster. I can just cut more of the firewall out and recess the center to allow the engne to be moved back the required amount, The only limiting factor is fitting, or being able to fit the heaterbox and A/C under the dash. But I'm sure, even if the plastic casing needed to be modified it can be done with a minimal amount of fuss.
I'm leaning more to moving the engine back for a few reasons. Firstly, the weight distribution will be much better, keeping the engine weight in it's S15 factory location for the suspension loading, whilst at the same time moving it rearward of the 510 engine location. Since there is next to no weight in the back of the 510, moving the engine rearward will work wonders for front to back weight distribution. Add to that, it will give me more room in front of the engine for maintainence, and also allow room for the Intercooler, A/C condensor and the radiator.
These mods are relatively easy to overcome, the biggest thing is the upper mount location. Moving the hub back 50mm, makes the strut stand virtually straight up and down removing all of the caster. I've ordered the coil over struts, and they come with adjustable tops. I'm hoping (I know it's not going to be enough
) there will be enough movement in it to get it back. Otherwise, I'm going to have to relocate the strut tower. Another downside to this is the ABS unit. I was going to put it in the factory S15 location, but if I relocate the towers, there won't be enough room, so I'll have to make custom brake lines etc. Here's hoping...
Anyway, here's a couple of pics.
Here's a couple of pics to to show the small progress so far.