2 Door 510, S15 conversion

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muvro
Posts: 26
Joined: 07 Oct 2014 19:46
Location: Sydney

Re: 2 Door 510, S15 conversion

Postby muvro » 19 Mar 2015 03:50

It'd make the bay look super smooth! As you said, it'd be a pretty tight squeeze. Lol I have a feeling there is going to be done clearance massaging either way.

muvro
Posts: 26
Joined: 07 Oct 2014 19:46
Location: Sydney

Re: 2 Door 510, S15 conversion

Postby muvro » 11 Apr 2015 04:30

Sorry for the lack of updates, been very busy at work.

I've had some good progress on the car. The rear suspension cradle mounting points have been fabricated and tacked in. S15 rear strut towers have been removed from the donor car, stripped down and fitted into place in the 510.

The MCA struts and Enkei Compe wheels arrived. The struts look awesome! They are the blue series and the cheapest in their range, but they are well made and appear to be made better than other products in the same price bracket. They are also designed as their road/track unit and valved internally to suit. The Enkei Compes are a great looking wheel, as well as being very light. Here's some photos.


S15 rear strut tower fitted into the 510

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Front strut installed. Note the camber adjusters in the hub bolts for the strut. Very clever idea, just swap out the different offset washer inserts for different camber settings, as well as having a large amount of adjustment in the bearing plate. The lower brackets were custom made for me to accommodate the extra angle the struts sit at.

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Rear strut installed

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Rear wheel installed, the offset and look is perfect. Can't wait to fabricate the flares.

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Front wheel installed. The offset appears to be much wider, not sure if it's the body that narrows or the hub face to face width is wider. Either way, I haven't measured as it doesn't really matter (I'm pretty sure it's the hub to hub faces that are wider on the front compared to the rear). I've purchased a pair of Hardrace adjustable front lower control arms, that should bring the hubs in approximately 20mm. Unfortunately, I'll lose 5mm of this due to the wheels not having enough x-factor to clear the brake calipers. So I'll get the wheels in as far as possible, then adjust the rear offset to get the best stance/look.

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I've got some more photos on my camera that I haven't downloaded. I'll get them up soon.

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McShagger510
Posts: 1739
Joined: 26 Mar 2004 20:55
Location: East Van, Canada

Re: 2 Door 510, S15 conversion

Postby McShagger510 » 11 Apr 2015 21:04

Just like Brutus the Barber Beefcake - cuttin' & struttin' !! :mrgreen:

Keep up the brave work!

James
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'72 2dr. 510 Turbo
'73 240Z all stock
'71 2dr. 510 stock......for now
'91 Nissan truck
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Pedro
Posts: 178
Joined: 02 Jun 2007 23:42
Location: Australia

Re: 2 Door 510, S15 conversion

Postby Pedro » 13 Apr 2015 23:08

Good progress!

muvro
Posts: 26
Joined: 07 Oct 2014 19:46
Location: Sydney

Re: 2 Door 510, S15 conversion

Postby muvro » 15 May 2015 05:05

Here's some more progress on the ol' girl.

Firewall reinforcing plate

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Fabricated steering column and pedal bracket bracing. I used the S15 steering column for a few main reasons, first is it's superior collapsing design, the standard column doesn't have a lower bearing support, so fabricating something to make it work would increase install time. Finally, the angle of the shaft at the firewall using the standard column was way too sharp. The S15 column is shorter to the uni, giving a much better angle to the rack. I also used the standard S15 bolt on seal tube, modified it and welded it into the firewall, so I could use the standard S15 rubber tube that joins the column to the firewall.

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You can see in this pic, the gearbox tunnel and firewall mods.

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Gearbox gator, I modified and used the S15 gator and mounted it onto a removable plate. The removable plate gives access to the gearbox shifter plate and allows removal whilst the gearbox is still in place.

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Gearbox crossmember fabricated to mate up with the 510 mounting position.

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Firewall port for the engine wiring loom, folded inward to replicate S15 port and ensure the standard rubber seal works as it should without sealer.

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Below are the upper 'A' pillar reinforcing gussets.

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Outer front rail gusset

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Front tie bar reinforcement and radius rod bracket mounting.

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S15 radius rod mounts modified to suit.

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Rear suspension cradle front mount brace. Again, I modified the standard S15 braces to suit.

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ABS unit installed and the brake lines mocked up. I use the factory lines to approximate the routing. I'll now make up brand new ones and make them neater.

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Mock up of what the flares should look like.

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At the moment I'm restoring a Jaguar E-Type, but it's an immaculate car and I've almost done the metal work, so I'll be back on the datto in a couple if weeks. I've started finishing off the rear strut towers, including bracing in between the towers via the parcel tray.

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two_68_510s
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Re: 2 Door 510, S15 conversion

Postby two_68_510s » 15 May 2015 06:17

You are a frickin' genius! That fab work is fabulous!! 8)

Best looking front guard support bracket gusset I have ever seen, very nice. I am going to steal your design.
Joel

2 '68 510 2 door sedans
'95 240SX
74 Jensen Healey

“We will either find a way, or make one.” – Hannibal

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Byron510
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Re: 2 Door 510, S15 conversion

Postby Byron510 » 15 May 2015 08:49

I also like your tubular transmission X-member design as it needs to take loads in multiple directions, complicated by the factory position of the 510 mounts. Good job.

Byron
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muvro
Posts: 26
Joined: 07 Oct 2014 19:46
Location: Sydney

Re: 2 Door 510, S15 conversion

Postby muvro » 22 Jul 2015 04:14

Finally managed to get back onto the 510 for a while, with some great progress.

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S15 rear strut towers finished and fully welded in. I'm yet to grind the welds, but that will happen. These are welded through the parcel tray, as well as through the seat bulkhead, which really ties them into the body and stiffens it all up, as well as ensuring the load is distributed well. I've also installed a tie bar under the very forward edge of the parcel tray, made from 3mm U channel. This ties the two towers together, along with stiffening the parcel tray up.

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Just a shot inside the wheel arch showing the strip I had to install to fill the gap after moving the wheel arch outward. It also shows the inside of the S15 tower.

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Rear wheel arch moved out and tacked onto place. What you see there is the the outer factory lip and the inner guard. I will be fabricating an outer section once the measurements and testing is finished and I've finished the inner guard off.

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Front guards are tacked up and ready for final clearance testing.

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PoorMtnKid
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Re: 2 Door 510, S15 conversion

Postby PoorMtnKid » 22 Jul 2015 07:54

This thing is going to be awesome. Love seeing updates.
looking for pass. side arm rest

510rob
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Re: 2 Door 510, S15 conversion

Postby 510rob » 22 Jul 2015 12:48

nice metalcrafting

sycklash
Posts: 52
Joined: 30 Jun 2014 17:34
Location: Nova Scotia, Canada

Re: 2 Door 510, S15 conversion

Postby sycklash » 22 Jul 2015 17:27

I love this build!
always watching for more updates!
Instagram: @Sycklash

Pedro
Posts: 178
Joined: 02 Jun 2007 23:42
Location: Australia

Re: 2 Door 510, S15 conversion

Postby Pedro » 01 Nov 2016 21:13

Any updates?


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