In the circle track cars I am use to racing, our brakes are absolutely terrible, so brakes are something I am definitely going to be looking at first. I've gotten really good at figuring out how to get the most out of stock junk. I'm not looking for a big high hp ride, probably something in the 400-450 range to the rear tires, but still want to make sure I have adequate stopping as I would like to do a few track days on occasion and run the mountains with my buddies as well on cruises.
When it comes to brakes, something that many seem to overlook is brake fluid. A lot of the time, the "fade" that people feel, is actually the fluid overheating and boiling and not the pads giving up. As you can see from this picture, the cars I race normally, generate huge brake temperatures. We are forced by the rules to run a stock caliper on the front and drum brakes in the rear, so having a good brake package really comes down to rotor design and pad selection along with good fluid.
My plan, will be get some good slotted and drilled directional rotors, probably going to upgrade to a 13" rotor as I have seen available. I will also be looking for the R33 GTR Brembo front calipers and will be looking into the Z1 motorsports 12.75" front rotor upgrade. For the rear, I'd have to do some more looking. I wonder if there is a way to put the stock front caliper and 11" rotor on the rear? I'll have to do some digging there. Aside from that, the brake fluid I will be using is what I use on the racecar and have never boiled once.
https://www.summitracing.com/parts/cao-all78115 It's expensive, but damn does it work well.
Strangely, you mention you've never seen a 91 for sale, but the one I was looking into is a 91 haha!
https://treasure.craigslist.org/cto/5853363082.html
I don't mind at all doing an auto to manual conversion. I've done a few before on S13's so it can't be very hard.
I still have much research to do. One of the biggest things I keep tossing around in my head is twins vs single. If I am going to be putting an RB in this thing, I want it to have great driveability and response. Trying to figure out if twin GT28RS's with BOV's recirculated will drive and respond better than a single GT3071R Twin Scroll with it's BOV recirculated. I don't mind doing the work or spending the money for either. Both will likely require modification but the twins with stock RB26 manifolds and an extrude hone may possibly do better. Another thing that's just going to take some looking and searching and looking at lots of dyno graphs understanding every car is different and in the end, just taking a chance lol
Suspension wise, coilovers are a must for sure. I have always been partial to the BC Racing coils and have used them on all my 240s as well. I'm not looking to make it a hardcore racecar, so I don't really need anything super special. Just want some adjustability and something somewhat solid. I know the BC's have always worked for me so it's probably going to end up being them.
Once I find a car, I can start really digging into plans more and more but I appreciate the list of things to look for. This will likely be the last toy car I have for a while so I want to make it count.