1498 replies to this topic

[Ben_O]

It has to be done sometimes, just have a look n think **** what have I done....... hahahaa

Absolutely!

 

next step is... well.... the step  

 

Then the Hinge panel and then the inner wing/flitch, then we will have an opening and closing door!

 

Then back onto it's side for the half heelboard, slinging brackets and other miscellaneous bits followed by the outer sill, quarter panel and wheel arch tub.

 

 

Then onto the other side   

[Ben_O]

Oh and not forgetting the jacking point!

 

Now i'm thinking that i will forget to fit it 

[Carlos W]

No progress today, I just went out there with a coffee and had a look to gauge my next plan of attack 

 

 

 

Run out of milk?

[Ben_O]

 

 

Run out of milk?

 

No mate, It's Espresso, 

 

Didn't anyone notice the tiny cup?

[Ben_O]

[Mini-Mad-Craig]

Awww it's diddy! mini sized

 

Looking stunning Ben. Amazing work.

[Ben_O]

 

 

Looking stunning Ben. Amazing work.

Thanks Craig! The Mini is coming on well too 

[Ben_O]

Right so i had all afternoon on the Mini today which was good as it has allowed me to make quite a bit of progress.

 

First on the agenda was fitting the A post reinforcer but before i could do this i had to get rid of my terrible attempt at the lower dash rail repair that i did last year.

 

Lopped that off out the way 

 

 

And then remembered that there is a reinforcer that goes between the front parcel shelf and the A post reinforcer so i dug through my scrap and found the old one.

This is why i never throw away any panels until the welding is complete!

 

So this is it

 

 

 

And it goes in here

 

 

 

That other bit on it is the remains of the old a post reinforcer which i obviously don't need so i removed it and ended up with this

 

 

And yes that is my reflection in the cardboard 

 

So i found a piece of nice thick steel (1.2mm) and set about making a new one

 

So flattened the old one

 

 

Notice that i drew on it with marker so i would know where the folds should be

 

And then transferred it onto card

 

 

 

Then onto steel, cut it out and folded the folds and this is it compared to the old one

 

 

 

So that got a good dose of zinc and while it was drying, i offered up the new A post reinforcer

 

 

 

With it clamped roughly in place i took some measurements. The good thing about clamping it like this is that i can tap it back and forth until the measurements are spot the dog without having to keep undoing it and removing everytime.

 

So once the measurements were mm perfect, i marked it all up, removed it, cleaned the edges and then clamped it back before tacking it in place top and bottom and then one on the front parcel shelf edge for good luck

 

 

 

 

 

Then i offered up the step/A post panel to check the fit but before that, i lopped off a bit of the old A post and a bit of the old Quarter panel.

 

 

 

The reason i have left most of the Quarter panel on instead of just tearing the whole thing off is so that i can use it when lining up the door. Notice that i only cut the minimum off.

 

Anyway, back to the step panel, I clamped it all up

 

 

measured once, twice, three times a lady until i was happy with the height and width of the door aperture.

 

Then i removed it all again and seam welded the A panel reinforcer top middle and bottom, like this

 

 

 

 

That aint going nowhere!

 

So back to the little reinforcer i made earlier

 

Clamped it in place to mark the plug weld holes and then drilled them and re-clamped it

 

 

 

Then plug welded it all up

 

 

 

Followed by a quick wizz with the stone

 

 

 

I left the ones on the shelf slightly proud as it's all out of eyes sight

 

so with that done

 

 

i moved back to the step, Clamped it all back on again, measured again and again and again before scribbling on the car with a pencil to mark the cut lines

 

 

 

Chopped them out of the way and gave everything a good dose of Zinc

 

 

 

While i was waiting for that to dry, I drilled a kazillion holes in the step panel about 1" apart ready for plug welding

 

 

Linished that back and then put zinc on the mating surfaces.

 

At this point, i decided it would be a good idea to try the scuttle on as i was a little unsure if the A post was in the right place so i put the step/A post back on followed by the scuttle

To determine the height, i just needed to compare the overhang of the external seam on the scuttle to the A post external seam. This is what i found

 

Drivers side

 

 

Passenger side

 

 

Both the same.. Phew!

[Ben_O]

So off with the scuttle and time to press on with the fitting of this step panel.

So i measured it several more times and lined up the edges of the joins

 

 

 

I made a bit of a mess of trimming back the A post join as i couldn't get my cutting disc in properly without cutting the windscreen frame boxing panel to bits so i made do.

 

So seam welded and ground down joints coming up!

 

 

 

That front join wants a tap with a hammer as the edge is a bit wafty    Ill go back to that later

 

And then onto the plug welding. Clamps are your friend here as everything needs pulling up tight, especially up the a post section as the Reinforcer needs pulling to the shape of the frame.

 

so a few plug welds

 

 

 

i think it is very important to get your plug welds as neat as possible as it saves ALOT of time and noise grinding them up

 

So they met the grinding stone followed by a flap disc

 

 

And that is how you fit a step/a post panel!

 

So i wedged the door hinge panel tight in place so that i could have a go at hanging the door. I am very very dubious about the quality of this panel (Magnum) as it looks, well, wrong 

 

Anyway, i wedged it in tight against the A post and hung the door.

 

Got some lovely gaps for a quick knock up

 

 

But that is where my winning streak ended.

 

THIS IS NOT GOOD AT ALL       

 

 

Yes that is a 1/2 inch gap between the hinges and the hinge panel. I would need a hell of alot of shims to fill that gap!!

 

But look

 

 

Tight against the a post. I know the door is in the right place as it fits lovely in the hole all round and i know the A post is in the right place as the gaps at the front of the door are lovely too.

 

I think it's a dodgy hinge panel that is to blame. Has anyone used these and what results did you have? If it's just like that, then ill have to operate on it to make it fit properly.

Anyway, a few shots of where i stopped tonight.

 

 

 

Time to stop for a few days and try to formulate a plan.

 

Thanks for stopping by!

 

Ben

[1590gilbert]

you have the same problem as me but backwards, your gaps to big n mines to small(my missis tells me that all the time)

Most of my panels are magnum. I think my problems are due to dodgy repairs in the past and me lining stuff up by eye and whats there.

atleast you can see yours and move things around and get it right. I think mines close enough but I may have to have different check straps(like some rubber straps holding the door).

[Ben_O]

you have the same problem as me but backwards, your gaps to big n mines to small(my missis tells me that all the time)

Most of my panels are magnum. I think my problems are due to dodgy repairs in the past and me lining stuff up by eye and whats there.

atleast you can see yours and move things around and get it right. I think mines close enough but I may have to have different check straps(like some rubber straps holding the door).

Luckily, it's only wedged in and not welded.

 

I plan to take it off, shorten the width by 1/2" and weld it back together. I might see if i can find the old one to compare it too.

 

I hope to get the door fitted fully without any shims to something's gotta give!

 

Ben

[Carlos W]

Is it a genuine hinge panel mate?

Everything else looks epic

[Ben_O]

Is it a genuine hinge panel mate?

Everything else looks epic

MAGNUM 

[Wise Old Elf]

 

 

I just replaced mine but looks like i did it in a different order to you. 

I welded in the inner "A" post panel to the inner sill (shown in the pic) then popped the stiffener (Magnum) onto the door hinge studs and trial fitted the door. The flitch can be bashed back and forth to get a good gap. Then I welded the stiffener to the flitch and then fitted the door step. Gap looks ok on mine. 

[Ben_O]

 

I just replaced mine but looks like i did it in a different order to you. 

I welded in the inner "A" post panel to the inner sill (shown in the pic) then popped the stiffener (Magnum) onto the door hinge studs and trial fitted the door. The flitch can be bashed back and forth to get a good gap. Then I welded the stiffener to the flitch and then fitted the door step. Gap looks ok on mine. 

Thanks for that.

 

It's interesting to see the other methods of doing the job. I am certain that the A post is in the correct place. the measurements were within 1mm of the original and of 3 other Mini's that i asked measurements from. the door fits lovely all round, it's just that hinge panel. If the a post was in a different place, i still wouldn't be able to move the hinge panel in any further and i would have trouble with the gaps at the back of the door if i did.

 

Carlos_W just phoned me and says he has a hinge panel by a different manufacturer so he is sending it over for me to try. Hopefully, it's day saved.

 

Cheers

 

Ben