1065 replies to this topic

[Kam]

Bit of a useless update this, so feel free to go about as you were

Finally got some brake pads through, opted for the same ones I used before, ebc greenstuff for my minispares 4 pots, these have I think a low level warning sensor on them?



Not interested in any of that sensor rubbish, I prefer the usual method, when you hear metal on metal is time for some new pads......and discs

Also got my exhaust through, opted for a Play mini 2" big bore with link pipe, so no cat as I have no time for the global warming



Now, I have to say I have always had something against roll tip edges on exhaust pipes???? I mean really something......hate them with a passion, makes them look cheap and tacko, so as soon as I have a couple of mins free the ******** is coming off!

Anyway, I'm not sure if the link pipe will fit as its a different angle to my old rc40 one? We'll see

Got a bit stuck with the brake hoses using the original mini T piece but a quick look on Mr Monkeys build project sorted that - cheers fella

Had some made up braided brake hoses come through that I was waiting for, unfortunately I didnt cater for the fact the pipe coming out of the bottom of the original mini brake regulator valve that would go into a T piece would need to be short or at least a right angle as there aint alot of room till it will hit the top of the allspeed frame



If you bend it it would kink too much so got the angle grinder out and cut the hose in two

Only joking I started shaving away at the top of the frame to get a little bit more clearance, only in a small area so dont stress pipe bends round with no kinks





Note to oneself - next time get a banjo or 90 degree bend?

At least I did on the clutch master cylinder, this is the reason why, in way of the air filter ducting



Not in the way of the air filter ducting



Simples

Just need to hook up the other end to the clutch slave end, but the hoses are getting a bit busy round there, other two are for the original mini servo



Thats all, like I said, As you were

[HARBER07]

to be honest Kam, I personally wouldn't leave that pipe like that. Looks like there is still too much stress on that pipe, which on a braking system isn't ideal. Is there any chance you could move that pressure valve higher up, to remove some of that stress?

All in my opinion of course!

[captainjack15]

Not sure I'd risk that. Basically as Tom said, it's probs not worth the risk. Chance are that the frame will move up and down a little bit anyways so it'll put more pressure on it.....

[Kam]

It does look scary close in the picture actually, but its not that bad really?

Could maybe shave a bit more from the frame directly behind the bend to give a bit more angle to it, or move the reg up a bit but theres no kink in the bend currently

Or I could just get a new hose made up with maybe a 45 90 or even a banjo on it?

Cheers guys, will look into it

[captainjack15]

Or I could just get a new hose made up with maybe a 45 90 or even a banjo on it?

Cheers guys, will look into it

That sounds like a good idea.

Less to worry about then me thinks, peace of mind

[Kam]

I've ordered a 90 degree hose now to replace the one above, cheers HARBER07 and the captain for the heads up

I thought I might aswell hang the rear silencer by the rubbers to see if the link pipe lines up to my custom manifold



It dont look too bad so will tackle that another day, at least its there......or abouts

Apologies in advance - for the dust on the rear bumper, I did ponder whether to 'polish' it for the money shot, I feel dirty now

Made up my 4 pots and chucked them on, I thought I'd try for a laugh and put my 12" spare steelie back on......



It fits!!!! I thought the 4 pots were for 12" alloys only? Didn't know they fitted the good 'ol steels



Hmmmm.......This changes things......we'll see.............**traction**

I've decided to use my bodyshop skills (none) and chop up and fit the front fiberglass front, doesn't sound like a big deal but trust me, its me!

After some advice from the 16vmini lot I purchased one of these as I wasn't sure whats best to use for cutting fiberglass. Bosch multitasker (PMF 180E)



I'm gonna go at this weekend, so tried a small section earlier on to make sure it would cut and more importantly could I do it?



Straight in with no pre-drilled holes or anything or any tidying after Just hope that bit needs cutting!

I can't put the rad in or tidy up the wiring loom unless this front is on so? This is the other bit I've been dreading to do.......bodywork

[Kam]

Suck it up solider!

I hate electrics but I hate bodywork more! Mess up on electrics and your brown bread, mess up on bodywork and everyone will point and laugh!

Ok, this clubby front is gonna be my 'trackday' front but it still needs to look good, so wasn't looking forward to this....so decided to suck it up and just get on with it

Started off with the front grill, my fiberglass front still has the A panels on them (which I'm not using now) so at least it stands up on its own to help me out Got the grill on using my new super duper funky monkey (no relation to GingerMonkey) bosch cutting tool



Ok, ok, its only three small slots but every little helps

Speaking of three slots......





Found the drivers side top corner edge correct



But the pass side a little lower



This prevented the headlight cowling moving into position, so sorted that



Put the rest of the grill bits on for a trial fit to see where I stood







Cut out the large sections behind the center grill



Then the bit I was dreading.....knowing I could waste £180 and a trip up to the west mids by getting this wrong





Sorted, the Kam way - measure once cut twice

Its been about 6 months since I've seen my car with a front on so thought sod it, chuck it on just for the sake of it!











Bit stuck here though???? Does the clubby bonnet line drop or stay straight? Help!





I really need to weld some A panel fastener plates on the car then go from there, so left it like this for today



Also got some of this bad boy



Any problems tomorrow then the front is gonna be glued on! This stuff is supposed to be the dogs dangly bits, or should that be the tigers bits?

Volcano ash? Pfffttt I've got some proper volcano ash up my nose after cutting this fiberglass! Man, this is some awful stuff.....

[captainjack15]

That's some epic progress mate

Nice pictures too Although you'd get it done in double time if you didn't take any, but you'd get double beatings for not taking any

[Kam]

Although you'd get it done in double time if you didn't take any, but you'd get double beatings for not taking any

Actually, earlier on I hit that 'stage' when it was time for a picture then thought "sod it they know what I mean...."

Die hard me, for you guys, all for you guys

Next time though.....

[GreaseMonkey]

Screw having the Clubby front as a trackday front!! Keep it instead Coming on well

[Kam]

Cheers Mr Monkey,

Hold on, we got two monkeys here??????? Ones greasy and the others ginger??? Dam this forum is complicated stuff!

The clubman front wont stay, its there to interchange if my mood takes me, but the roundnose (like the other monkeys one) is still the goal, I got a soft spot for clubbys but got a softer spot for roundnose

And the Le Mans deadline is back on Booked in with the rollers on the 31st now but need to get it MOT, taxed and insured first and that doesn't include any shakedown time either, so as I said on another forum - life is taking a backseat now as I have more important things to do first

Bring on the pressure

[Kam]

I really dont like doing anything bodywork, I really definately dont like fiberglass, and I really really really definately dont like doing both together!

What a complete mare, made tens times worse by the fact I'm doing it, I've never cut fiberglass or tried to put on a front end before and I know why now! It aint on properly but its sort of on, half way there with it but the main brunt of it is done, never again.....

Started off making up some plates for the A panel



Welded some flanged nuts on there Kam style!



Then got ready to place them on







Gonna tack them on aswell, so A panel needs spraying up aswell now

Trimmed down those awful arches aswell



Then the nightmare bit, trimming up to get the front end to fit, my mistake as I cut a bit too much off the ends...... I measured up so many times on and off, little bit here little bit there, alot here alot there....oops - I blame my hangover

Well its on anyway, got 1 bolt on each A panel but none on the front so its still sags a bit





The worse bits are around the scuttle panel, I know where I messed up but gone past the point of no return now so just gotta get on with it. I would say unless you are a proper mini enthusiast you would not even notice it - NOT! There is some serious gappage going on here, should've asked for help with this really? Hopefully this engine is quick enough so people wont notice as I fly past

It still needs to be 'pulled' across a bit as from above the driver side its



But pass side is



Picture was taken before I pulled it across so its not that bad, also as I said it still needs two bolts in the front where the mini teardrops would have been. And a bracket made up to sit on the inner wings to give it some support at the back.

The whole suspension still needs to be sorted out anyway, I've just bolted things up to get them on, so caster, camber and toe in/out are all over the place, you can see from the front the toe in/out need looking at

Plenty of room now







Little bit more cutting and finishing off to do then I can start on getting the rad in and sorting out the headlights, still need to get someone to paint up this front end aswell....

I have now decided this will be my trackday front, and I really hope I aint doing any trackdays this year

God I hate bodywork, even more so now

[Kam]

Got a few days off work now, for the mini? No, for the usual household living boring stuff that needs sorting out

Unfortunately I have no time for all that nonsense so the mini it is!

Started off plumbing the rad in, did this the Kam way....chuck it all in and worry about the other stuff and where it goes at a later date





Looks fine to me, it'll be ok

Got my new made up braid for the brake regulator to the T piece with 90 degrees either end......



as my last one was errm shall we say a bit tight?

Its a bit spaggehti junction but that just means more fluid right?



Then hooked up my clutch master to the pedal and only had half the pedal travel??? Was a bit stuck on what to do about this so I went for lunch (lunch is for wimps?) then pulled the master apart and extended the clevis point as mine is the AP one on a threaded bar and raised the master a tad on the bulkhead



After much kafluffing around I now have full pedal travel and the pushrod goes almost the full length in the piston, but this is without any fluid or engine running so will see what happens later on, beauty is it can be adjusted, if you include getting the clevis pin in/out a beauty

Was bored on ebay a couple of days ago but bought a cable stopper anyway, as you do



I'll chuck it on the end of the throttle cable for the pedal and if its needs adjusting at the rolling road then no worries, this is from a lawnmower believe it or not, believe it not further but its a honda lawnmower aswell!

Then the biggie of the day - the gear linkage

I was bricking it as I've read doing this to death but theory is one thing and hands on is another, took me in total seven hours!

This is for anyone that doesn't know as I'm trying to go into detail for things some people dont bother with on build diarys

Actually I didnt know which way to tackle this as you can make it to your setting but I haven't got my exhaust in it so wasn't sure of it hitting anything so went about it the Kam way

Chopped it in half



Hooked up either ends to the engine and gear stick respectively



Needed a mate to hold the stick central, all mates at work so went for another lunchbreak.......



Came back refreshed (kfc is awesome lunch!) so went at it!

Used a G clamp and bit of wood to hold it central



But needed to make sure it wouldn't move so.....as you do.......I chucked a 10 kilo weight on it



That effer aint going anywhere

Pulled up all rods and marked off where they meet and took it all apart and got ready for welding



Compared with the old mini one, just for nostalgic purpose really



Added on my mini gear gaitor and gear knob



The gear knob dont fit, different thread, but was held on with some super tape for the money shot

Question is? Does all the gears work? Dunno, lets see.....



Nice bit of crunching......

I'd imagine it may be different with some fluid in the clutch system and the clutch pedal pushed with the engine running but I dont care, I was estactic it actually got all gears!

Next I started on the clutch res pot for the master cylinder, didnt know what to do or where to mount it so once again the Kam sytlee.......

I cut off some inner sections and turned it up 90 degrees so the holes would be sitting 90 degree and not flat as standard



Mounted it just under the drivers side bonnet catch using an existing screw hole which would of held the relay holder. Sliced off a small section on the inner wing top section so cap can come off



Should be okay

Left it as that



Rolling road is booked in for 9 days times and I want to drive it there and thats with tax and MOT but got this through the other day from DVLA



I'm now gonna call this the 'Gingermonkeybadboyletter' I was expecting it anyway but thought I'd try

As I've been popping into my local honda for parts lately they said they would put something in writing to try and help out so we'll see....

Edited by Kam, 22 May 2010 - 09:46 PM.

[GreaseMonkey]

Great stuff Kam, how nice to see the Holy fifth gear slotting into place in the video

[HARBER07]

Brilliant work Kam, Loving the gearchange vid . Really pleased you sorted that brake pipe out too, as Jack said, its one less thing to worry about