609 replies to this topic

[minisi35]

Hi thought it was about time to show my new road rally mini, my old cooper is getting very tired so ive finally pulled my finger out and started this project, hope you enjoy the progress

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first signs of rust  15092010332.JPG   2.9MB   60 downloads

[minisi35]

few more pics of what i started with. I had never welded before so i bought myself an angle grinder and a welder and with a bit of advice from friends i made a start

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[minisi35]

[minisi35]

measured the new panel


then bit the bullet and started cutting

[minisi35]

Im quite pleased at my first attempt with a welder

[TopCatCustom]

Looks a lot better than some I have seen!

[minisi35]

Looks a lot better than some I have seen!

Thanks, as im doing more its getting better, plus buying a really good helmet has made a difference

[minisi35]

The arch was quite badly corroded and as ive got to fit the roll cage to the front of the arch i need it strong so i started cutting

as you can see the subframe mounting panel was also shot so i took a couple of days to weigh up how to line it up then just got on with it




the red paint is where ive seam welded around the top of the shock mount

plug welded then seam welded where possible

[minisi35]

once the arch was in it was time to fabricate the corner panels, the corner panel ws pretty rotten so that was cut out so at least i had some new metal to weld to



this was my second attempt at this one as the first time a kept blowing holes in the old metal so i stepped the piece of metal and plug welded it first(see the first pic), then tacked the outside

[minisi35]

tidied up the boot with seam sealer


decided i needed a bit more practice with the welder so seam sealed and strengthend the rear subframe

and built a works dash as a friend gave me some templates

[minisi35]

had a break from the project over christmas, had to do some work on my current rally car as i was course car on a local rally.


Thank god Minifair gave me some inspiration to start working on it again

[minisi35]

I had cut out the rear of the sill/innersill to do the subframe mounting panel this is the repair piece i made out of the old rear bins to fix it

test fit

plug welded to fit then seam welded to finish

[TopCatCustom]

Old skool British motor vehicle repairs, using left over parts to patch up! I like it

[minisi35]

i wasnt happy with the seam sealer job so i broke out the thinners wiped it off and started again. While i was at it i removed the rear seat squab



The finished article, you can see the scorch marks where i added extra welds to the seatbelt mounts. Also i welded the little grommet holes. The centre seat support is left in as we have to run with rear seats in ,so i left it there to support and i fill also use it for strapping down the seat

[minisi35]

Old skool British motor vehicle repairs, using left over parts to patch up! I like it

oh im all for recyling