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500 (Classic) Enzo the Cinquecento - RestoMod

Introduction

Enzo the Cinquecento - 500L 110F RestoMod

Hi Everyone,

I bought a 1970 FIAT 500L in November of 2015 with my goal being to have a classic car that I could restore over time, and make some modern improvements along the way. Ideally the car will be a car driven only maybe 1 or 2 days per month, but also be improved so that I can do classic rallies, hill-climbs and social motorsports.

I've always loved the Abarth cars from that era, so the exterior aesthetic styling will be Abarth-based, and the interior will be a more modern GT-style (neat and functional).

The existing 126/650cc engine in the car has been plagued since I bought it so I have now taken the car off the road to commence a large chunk of the work.

Planned works include:
  • Motor
  • 780cc IL Motore competition motor - ORDERED
  • External oil cooler with logic-controlled thermofans
  • ELX ignition
  • Transmission/Driveline
  • Assess gearbox for actual current gear ratio set and final drive
  • Look at options for differentials/LSD
  • Exterior
  • Roll guards to avoid tyre scrub on outer edges (145/70,12) but upgrading to 165/55, 12
  • Install Abarth badging
  • Install raised engine cover
  • Research composite aerodynamic hard roof options for competition spec
  • Abarth Corse mirrors
  • Abarth wipers
  • Bonnet catches front and rear
  • Interior
  • Strip all existing carpet
  • Replace with new carpet or alu/composite floor plates
  • Remove original seats, replace with 2 fixed composite SPARCO bucket seats
  • Remove rear seat entirely, create replacement panel over firewall with sound and heat insulation
  • Replace steering wheel with SPARCO 3-spoke, small dish suede wheel
  • Modify gear shifter to allow for shorter mechanical throw but with more clearance of seats with SPARCO gear knob
  • Replace dash with custom layout, composite wrapped in alcantara
  • Install Race Technology DASH2 (oil pressure, oil temp, air-fuel ratio)
  • Install 2 x HANHART mechanical chronometers for classic rally
  • Modify SPARCO pedals and look at options for brake BIAS adjustment
  • Chassis
  • replace current (lowered) leaf spring suspension with adjustable 2 or 3-way coil-overs (need to research options)
  • strut brace for front towers
  • need to establish rigidity in rear frame and asses if brace required in rear
  • Brakes
  • 4-wheel disc brakes
  • hydraulic handbrake
  • Electronics
  • Strip and re-wire the entire car with a custom mil spec loom
  • Include loom pairs/plugs for sensors (engine, chassis, brake etc)
  • Fuel
  • Remove small fuel tank and replace with larger capacity rated fuel cell
  • Electric fuel pump
  • Wheels and Tyres
  • Yokohama A048 165/55,12
  • Currently has genuine Borrani 4.5,12 wheels. Will keep these for the road.
  • Create custom "turbo-fans", need to assess base wheel for this modification

I have already laser scanned the car to work on some component design, and to do 2D and 3D CFD on the body to look at aerodynamic options to improve engine performance (RAM air box), and also engine cooling, plus optimised location for oil cooler.

I won't have a lot of time to constantly update this, but I will do my best to upload shots as key things are ticked off the list.

I hope to get advice from other owners on a few key parts, as there are a lot of shops out there selling the same stuff, but in my research not many people seem to be using it!

Some of the purists won't like what I'm doing to the car, but my goal is not to jeopardise the shell at all, as that's where this cars value is. I'll be keeping most of the original parts I take off, so I can always restore it back to normal in the future. But I hope everyone appreciates what I'm trying to achieve with this project.

Cheers,
Renato (and Enzo)
Re: Enzo the Cinquecento - 500L 110F RestoMod

Ok, so this has taken a lot longer than anticipated. I’ve now got two children and less spare time than ever, but I have started working on the project again.

I had the car on the original suspension, wheels etc to make it easier to move around, but recently advertised those parts via my local owners club as I don’t have the space to store the old bits.

The car is now up on stands, and I’m in the process of test-fitting new parts and fabricating others. I’ll try and update this more regularly now.

A couple of snaps from the workshop.

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Re: Enzo the Cinquecento - 500L 110F RestoMod

Spent a couple of nights working on some of the Interior/dashboard items. Before I can complete the custom loom, and need to know where dash, switches etc will be.

I installed the custom alcantara covered dash I made, to ensure correct placement, then updated my laser scan data for my CAD model, and setup a new workspace in Fusion 360 (previously using SketchUp).

I created a couple of very basic bezel shapes to test-fit, before then creating the complete dash body, incorporating a cover panel for the top/end of the steering column mount.

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Then 3D printed a low quality rapid prototype of the shroud for test fitting

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Then made the steering column cover as a separate item, so I could get both parts perfect fitment, before printing them as one final part
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Once all parts fit well, printed them as one complete part in higher quality carbon fibre filament.

Final print is roughly 8h30m print time

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Test fitment of the dash unit and switch looms
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Then test fit entire unit onto dash
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The entire interior has been laser scanned, and all parts have been made in 3D CAD, even with that level of detail, I’m still happy to have produced a perfect audibly pleasing “click” fitment at first try.

This part is 160grams in weight, and cost me less than $5AUD to print.

The dash shroud will now be finished with sanding, and twill carbon, but I will wait to do all of the composite layups at the same time, so I can be as efficient as possible with resins and the cleanup in my work area.

Next job is to fit the knee protectors (which I need to upholster in leather), so then I can scan the next part of the interior to update my model so I can design the main central dash panel for all switches etc.

Have a bit of travel coming up for work, so will have slow progress again for next couple of weeks.
 
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Re: Enzo the Cinquecento - 500L 110F RestoMod

Right, so, progress is slow.....

I’ve upholstered the knee protectors, and done a test-fit. I’m not sure if I like the black leather on the grey alcantara. But the fit is really good. (The shadows on the picture make it look like big gaps, but it’s a very good fit). The color match may grow on me.

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A quick snap looking down the barrel from my driving position, really happy with how the ergonomics are shaping up for me (182cm tall)

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