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Lulu's Restoration ('96 Cooper)


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#1 wardyxxx

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Posted 26 June 2010 - 08:05 AM

Well, I've had Lulu for about 3 and a half years now and i've only had some minor work done apart from the front end and sorting the gearbox out.

So, I thought I'd bite the bullet and give her a full resto.

Here's what she looked like prior to the resto:

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The sill was bubbling up really badly and had been bodged with a sill that wasn't even for a mini! I didn't help the matter by poking at it and making a MAHOOOSIVE hole in it!

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The rear quarter part below the rear windows both sides had bubbled up quite badly too.

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You can't really see, but a smashed a huge hole in the rear valance by backing over a bucket. That was my first cleaning-related injury!! And after I did this, I saw that the rear valance was reaching the end of its life too!

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Both sides of the front wings were pretty well made of just filler, they lasted pretty well and didn't look to bad, but there was pretty much no metal left on the wings either. And I must've hit a block of ice over the winter - I smashed off a chunk of the front panel on the near side.

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She didn't look too bad from a distance!

But then I was launched into a world of issues!


So, I'm having:

2x wings,
2x a panel,
1x front panel,
2x inner sills,
2x outer sills,
1x boot floor,
1x rear valance,
1x hinge plate,
1x passenger door,
2x inner wings,
2x rear quarter repairs.

Central locking,
New carpets,
Soundproofing,
Boot liner kit,
Mpi wheel, stalks and steering column,
Oh, and a good service!

Here we go then! :S


Edited by wardyxxx, 25 May 2013 - 06:19 PM.


#2 wardyxxx

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Posted 26 June 2010 - 09:18 AM

Got the wings off and had a good look. Uh-Oh!

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#3 wardyxxx

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Posted 26 June 2010 - 01:16 PM

Bit more of an update; got the carpet and seats out and had a good look at the sills.




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Heart attack time!! :S

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#4 danie garry

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Posted 26 June 2010 - 05:27 PM

ouch! was that on the road??

#5 wardyxxx

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Posted 26 June 2010 - 05:53 PM

Aye. But she wasn't like that, thats with the weakest metal taken out, there wasnt any mahoosive holes until I started removing the rust. just need to cut the last few mm away to get to nice metal to weld to.

I'm shocked at how badly these later mini's go rusty!

#6 mk1leg

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Posted 26 June 2010 - 06:13 PM

That sure has the dreaded tin worm and good to see your doing something about it...............keep pictures comming............. :(

#7 Teapot

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Posted 26 June 2010 - 09:39 PM

Gulp.



At some point I'd better show Mrs T this thread to prepare her for the exploration of Rocky in the autumn.
So please tell us about the happy ending first!

#8 wardyxxx

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Posted 26 June 2010 - 09:52 PM

So please tell us about the happy ending first!


Will do!

There is no force upon this earth that can stop me getting Lulu back on the road!!

#9 wardyxxx

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Posted 27 June 2010 - 08:16 PM

Had a look at the other wing today. Tin worm!!!!!!!

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#10 sonikk4

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Posted 27 June 2010 - 08:19 PM

Nice and crusty but very repairable, good luck with it.

#11 wardyxxx

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Posted 28 June 2010 - 05:04 PM

Had some goodies arrive today:

Grille Kit:

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K&N air filter,
Oil + filter,
new plugs,
New boot seal.
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#12 wardyxxx

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Posted 15 July 2010 - 04:37 PM

Right, update time!

Removed all the remaining rust around the rear quarters

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Got on with the front:

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Getting there!

#13 wardyxxx

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Posted 22 August 2010 - 08:19 PM

Sorry for the lack of updates.

Inner and outer sills have been attacked....
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....along with the floors both sides!
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Sorted the subfame mountings out. We removed mainly pure filler, and a little bit of cardboard! :thumbsup:
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Put a bit around the rear bins too.
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Lurvvvvvvvvvvvvvvvvvvley new, clean and fresh sill! :D
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These later mini's are a nightmare!

What do you all think?

#14 Pitcrew6464

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Posted 23 August 2010 - 08:41 AM

cool progress got your work cut out! i think the later coopers were made with a lower quality grade of steel hence the reason they rot so danm quickly!

#15 all4sreturns

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Posted 24 August 2010 - 05:52 PM

Blimey, can't believe how your poor car has been eaten away by unfriendly tin worm!!
I used to have a P reg mpi cooper (before the Mrs wrote it off an went to the scrap heap in the sky).
That was going a similar way to yours. Makes me feel very lucky with my 1970 Morris body. After stripping it to bare metal, I was extremely lucky to find only a small hole in the floor pan needed welding.
Hope Lulu's back on soon! (Broughton is too quite now that's not blasting around!) :huh:

Edited by all4sreturns, 24 August 2010 - 05:52 PM.





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