852 replies to this topic

[JonnyAlpha]

Some nice progress here mate. I know what you mean when you say that working on it too much causes some mistakes.

 

Shame to hear that your project is going to be laid up for a while but perhaps it will allow you to come back to it with a fresh head.

 

Good luck with the new job

 

Ben

Thanks Ben

[JonnyAlpha]

Well it's been five months since I last worked on my Mini or posted any updates on here. I have been too busy now I have started work (Teaching) and it's just too damm cold in my garage :-(

 

I am hoping to do something next wee (half term) and then over the Easter holiday.

 

The work left to do is:

 

LH side floor (middle section only).

RH side floor from under the companion bin to the front well.

Probably have to re-do the RH foot well, repaired previously but they just welded a new floor pan over the top of the old floor.

RH cross member outer

LH / RH Jacking Points

LH Flitch Panel / Scuttle / Rear Corner of Inner Wing

LH and RH Sills

LH and RH Panels (Small sections that cover the subframe mounts)

Another coat of Epoxy under the rear end and floor repairs

Seam Seal all repaired areas

Prime all repaired areas

Stone Chip floor

Top Coat Floor

Renew both track rod ends (already purchased)

Rebuild Subframe (All parts ready I think)

Fit Subframe and get the damm thing rolling again

Prep for MOT

 

Probably missed a few bits out but that should get it rolling at least, at least two weeks work (if I buy the panels and don't make them myself)

 

I'll update as I go as before and hope (fingers crossed) to actually drive it to this years National Mini Cooper Day (camping) and the Legendary North Devon Grand Tour (which is back on this year apparently).

 

Wish me luck...........

[Coxie]

If you get it done for the national cooper day I'll drive down with you as mine is up and running now.
What condition is your boot in ? As I have a rust free one left over from my build.

[JonnyAlpha]

If you get it done for the national cooper day I'll drive down with you as mine is up and running now.
What condition is your boot in ? As I have a rust free one left over from my build.

Coxie, sounds like a plan for the Mini Register, ref the boot, sadly if you skip back a page or so that,s the area I have done most of the work on, now all primed ready for seam sealing etc:-)
You haven't got any floor sections kicking about have you, still need to fill some areas from the companion bins up to and under the cross member, you can't by a mid section. Also have to repair the RH cross member and make or buy two Jacking Points.

[finch661]

Just been reading this thread, its amazing. love the idea of fabricating all the panels - i have been taking notes as my boot floor looked like yours!

 

keep up the good work!

[JonnyAlpha]

Just been reading this thread, its amazing. love the idea of fabricating all the panels - i have been taking notes as my boot floor looked like yours!

 

keep up the good work!

Thanks,

I learn't a great deal doing all of this work especially metal fabrication but making all the pieces from scratch was only possible due to the spare time I had. If it wasn't for all the fantastic advice from some very helpful people on this forum and on Retro Rides I wouldn't have achieved what I did.

 

I don't have the luxury of time any more but not a lot of spare cash so progress will be slow, I'll be back at it next week (half term) and will hopefully have a roller again. (that's a rolling chassis not Rolls Royce)

[Nicholson14]

Just had a good read through your thread, awesome rebuild, your fabrications brill! Making some notes as I've got a HUGE amount of body work repairs to do myself, it's going to be a long job! Also loving the colour of the wheels. I hope your managing to get plenty done through half term, looking forward to seeing the progress

[Coxie]

If you get it done for the national cooper day I'll drive down with you as mine is up and running now.
What condition is your boot in ? As I have a rust free one left over from my build.

Coxie, sounds like a plan for the Mini Register, ref the boot, sadly if you skip back a page or so that,s the area I have done most of the work on, now all primed ready for seam sealing etc:-)
You haven't got any floor sections kicking about have you, still need to fill some areas from the companion bins up to and under the cross member, you can't by a mid section. Also have to repair the RH cross member and make or buy two Jacking Points.

No sorry mate I haven't got any panels at all. I was blessed with a rot free shell and only replaced the sills for piece of mind.

[JonnyAlpha]

Just had a good read through your thread, awesome rebuild, your fabrications brill! Making some notes as I've got a HUGE amount of body work repairs to do myself, it's going to be a long job! Also loving the colour of the wheels. I hope your managing to get plenty done through half term, looking forward to seeing the progress

Thanks Nicholson;

Just about to get back at it, updates to follow

[beaubrad]

Looking forward to seeing your updates

[Minidarren83]

Wow i don't know how I have missed this thread excellent work

[JonnyAlpha]

Looking forward to seeing your updates

Thanks 

[JonnyAlpha]

Wow i don't know how I have missed this thread excellent work

Many thanks 

[JonnyAlpha]

OK I was all set to get going today but last night I was up at 02:00 with stomach ache anyway absolutely knackered so didn't get up until late and only got going at 11:00am.

 

I was lucky with the weather today which meant I could clear out the garage an make some space, I put my refurbished Subframe and Wellers in the conservatory, hope the missus won't mind

 

First job fit some new wheels to my compressor, not really Mini related but I am fed up with dragging it in and out of the garage on one wheel. The axles are 16mm dia and I could not find any wheels to fit. I did pick up a pair of wheels last time I passed Trago Mills, they are 13mm internal dia but enough meat to drill out.

I did't have a 16mm drill so made do with what I had.

 

Once they where drilled out a little silicone grease for good measure and hey presto finally new wheels

 

 

Before I restarted the Mini I reassessed what work i could achieve this week, I would really like to get the floors and sills finished so that I can re-fit the subframe but this will be pushing it.

I hadn't planned on doing the RH footwell as it had a repair panel fitted already but when I took the RH sill off it was clear that this was a complete bodge job.

 

The footwell repair has been slapped on top of the old floor and it actually looks like this had been done to an extent already making three layers!!! (two layers of rot and one layer of ok ish metal).

 

The floor on the underside is rotten so it looks like I am going to have to tackle this after all, I did have a picture of this but I appear to have deleted it :-(

 

Anyway after a few minutes deliberation about whether to start cutting out the RH foot well but instead I decided to instead complete the LH floor, that way physiologically it would seem like progress.

 

Here's the area that I would concentrate on:

 

The cross member is reasonably OK:

 

   

So first off I measured up the area which extends from the front of the companion bin and under the Cross Member, I have a couple of pieces of sheet metal left which would be long enough but neither are quite wide enough to fill the entire area that has been cut out.

 

First off I set about getting a R/A corner and a couple of straight edges to work from:

 

 

That's not my line on the RH edge!!! 

After marking it - straight - I cut off the excess with my snips:

 

 

After getting the main edge square using the upper edge as a start  (the top of the door step) I marked a line for the first bend but before making the fold I cleaned up the existing paint, otherwise it would be difficult to do once bent.

 

 

Now with the first fold done I started to measure up the front edges by overlaying the repair piece.

 

Next I marked and cut out the rear edge, I decide that the edges of the inner sill would be butt welded, the floor however would be joddled and lap welded.

 

 

Next I joddled the rear edge and once the rear and front where lined up and in place I marked and made the last fold:

 

 

Here's the piece in place:

 

 

That's all I had time for today, slowly, slowly, tomorrow I'll trim and joddle the floor and weld a patch to cover the area that you can see under the small mole grips on the RH side in the picture above.

 

Must not forget to cut a hole in the inner sill where the rear seat belt mount fits (might have to buy a set of hole bits).  

 

Finally its looking less like a Flinstones mobile.

Edited by JonnyAlpha, 16 February 2015 - 08:27 PM.

[Ben_O]

Nice bit of fab there mate.

 

Been doing a fair bit of that myself lately. It really saves on spending out on panels.

 

Ben