230 replies to this topic

[panelbeaterpeter]

Well it's been a while since I've worked on my own mini, mainly because I took Flo off the road last September, and bought this stunning machine as a winter runabout..


Now the time has come to get Flo back on the road. I decided to sort out a few areas had been bugging me, the plan was to fit 2 new outer sills, the N/S door skin, sort out a little area of bubbling on the bonnet, a few little dents, change the wheel arches, and fit a new interior. However things are never as simple as they may first appear..

Somehow I managed to wangle some space in a workshop, so yesterday I went and picked up the mini from it's winter hiding place. Started first time, not bad after 6 months sitting! I drove it into the garage and jacked it up, ready to attack the O/S sill.


Looks pretty innocent..


Nasty sill


So I cut off the sill, to find lots of rust waiting for me inside..






Something tells me I need an inner sill

At least the rear didn't look too bad..


After a bit of digging, I realised the floor pan needed attention as well..


And the flitch looked suspicious too..


I cleaned up the reverse, and found a big plate.. I'm quite ashamed to admit that I think I did this when I first got the car, and had justed started in a bodywork garage.. although it was so long ago I can't actually remember.


So I cut out the rust on the floor pan


Made and tacked in a plate


And the same with the flitch



Cut out the rusted section of the inner sill


Made a new inner sill and welded it in

[panelbeaterpeter]

After a bit of digging at the rear of the sill, I found the hanging bracket and the floor around the rear of the bins was a little corroded..



As was the heel board, and rear subframe mounting point..


Obviously all that had to come out, but I really didn't want to get involved in removing the subframe.. so like the coward I am, I attacked it from behind.

Heel board and subframe mounts cut away


New heel board made and welded in


Floor corrosion cut out


And plated


Rear section of the inner sill made up and welded in


Rear subframe mounting point made, and welded in.


And that was Saturdays work done..

[panelbeaterpeter]

Today, I had another rummage, and found more rusty treats lurking in the rear bin..


Cut out



And welded up.. not pretty I know, it's kinds difficult getting into the back of the bin when you're 6 foot 4 and the mini is a few feet in the air.. Excuses? me?


The rear hanger bracket was a bit past it's "rust before date" so just in case there aren't already enough rust traps on my mini, I made up a new one..




And welded it on


I then dressed the welds on the floor, flitch, and inner sill




And found another little hole.


Rust cut out, plate made, welded in and dressed



I then gave the inner sill a coat of etch primer, and a good thick coat of stonechip, just to help protect it from the elements.

I didn't bother refitting a jacking point, useless rust traps in my opinion, and anyway, who ever uses theirs? I'd always be scared of the jack going straight through the floor. Not that that's ever happened to me before or anything.. So anyway I blanked off the jacking point hole


And painted the inside of the sill with weld through zinc primer.


And clamped it on the car ready for welding. Please note, you can NEVER have too many pairs of mole grips.


And welded it on


Then I etch primed the new sill and the floor, and stone chipped the floor.


I also applied new sound deadening to the floor, where I removed the old stuff to prevent a pyrotechnic display when I was welding.



It is at that point, that I decided to go home.

Hopefully I'll be doing more next week.

[Shifty]

So, have you finished it yet??

[shorty]

is it costing alot less in making your own panels and stuff then rather than buying pre made pannels.

its coming along nicely though

[mighty mini jack]

Nice work Pete, thanks for the picture of the gaping hole earlier.

[panelbeaterpeter]

is it costing alot less in making your own panels and stuff then rather than buying pre made pannels.

its coming along nicely though

Well, all that cost me nothing apart from the outer sill. I would have bought the inner and the subframe mount etc if I knew they were gonna be like that, but I couldn't be bothered waiting a week for the bits to arrive! Just impatient I guess

[bert998]

Showoff.

[Scallywag630]

Its a comforting thought that the more rust you find, the better the car will be when finished. Looking good, keep up the good work.

[panelbeaterpeter]

So, have you finished it yet??

Trust you..

[GreaseMonkey]

Showoff.

x2

Hehehe

[panelbeaterpeter]

Its a comforting thought that the more rust you find, the better the car will be when finished. Looking good, keep up the good work.

Yeah, and also quite alarming that a car can be that rusty, and you don't know about it!

[panelbeaterpeter]

Showoff.

x2

Hehehe

Haha shut it you two.

[bert998]

im shocked to see what its like under the surface, it looked mint last summer.

[Nick '91]

Where did you store it over the winter? In a stream?

Admiring your ability (with green eyes) to make up replacement parts.

Flo's looking great.