670 replies to this topic

[big-jay]

Just read it all. Very impressive and coming Along very fast.
Do you have any problems when welding the painted items (like sills). I can't weld but few welders I have spoken too say not too since it may catch fire or not penetrate. As I say, I can't weld just there comments. If it's ok, then I will get all mine painted. Normal paint?
Thanks

Hi Steve, thanks for the kind words.

I always paint everything first if I'm going to be plug welding. I use a zinc based primer for flanges and then apply top coat, then when the two pieces are clamped together I scratch away the paint where Ill be welding the plug if that makes sense. If seam / pulse welding I don't use any paint until after. I painted the inside of the sills as I won't be able to get in there to do so after there welded on, you could just use some form of cavity wax instead but I opted to use both paint and wax as I want this car to last ! As for catching fire, I've never really had that happen to me, I usually just get a small amount of bubbling in the paint around the weld which I easily sand back down and re-paint after. I hope I've been some form of help to you

Jay

Edited by big-jay, 27 June 2014 - 10:56 AM.

[Minimad100]

Just read it all the way through!! You're making good progress!! I'm looking foreword to see the finished car!! Keep it up!!!

[Minimoke8394]

Making good use of the workout bench there mate ;) Awesome work as per usual. Have you got a date in mind for completion or are you just taking it as it comes? 

[big-jay]

Just read it all the way through!! You're making good progress!! I'm looking foreword to see the finished car!! Keep it up!!!

Minimad100 - Thanks, So am I !

Making good use of the workout bench there mate ;) Awesome work as per usual. Have you got a date in mind for completion or are you just taking it as it comes?

Minimoke8394 - Workout benches work very well as a parts holder haha, and I would like to try and get it done for Himley Hall but we will have to wait and see !

[big-jay]

Update,

I've started chopping out the rot in the rear, there is more than I was hoping, but it's not too major.

The problem area -



It wasn't too bad in the other corner but I've chopped it out for peace of mind.

Chopped out the rot -





I wasn't planning on removing the boot floor lip flange but the other guy who fitted the valence cut it too short so it wasn't actually attached to anything.

Then I had to go about removing the valence closing panels, what a NIGHTMARE ! There's like 20 spot welds that hold it on to the subframe strengthener, so lying on your back on the floor trying to drill them all out was....interesting to say the least

Some pictures -





I may actually remove these strengthening plates and replace them with fresh metal but will have to wait and see what sort of size the boot floor repair panel is. I also removed the other closing panel but didn't take any pictures of this.

I also purchased some of this to get rid of some of the surface rust -



Now I did mention a while back that I would have a big purchase arriving at some point this month, and I have indeed.

Here's some pictures -













I sent my whole interior of to be re-trimmed by a guy on here. His company is called JCS Custom Trims and his work is top notch and his prices are more than reasonable !

I had them trimmed in black vinyl and black suede with red stitching and red piping, same with the door covers. I'm very happy with them and the pictures do not do them justice !

Couldn't resist trying them in the Mini -





It still looks like a Mini from this side -



Well that's all I got done this weekend, not one of my most productive weekends I must admit, but have been quite busy. Anyway more updates next weekend !

[big-jay]

Update,

Got some more done on the rear end this weekend.

I brought the magnum boot floor repair panel and cut out the piece I won't be using -



Then I drilled out the spot welds from the arch brackets as I want to leave these in place to act as a datum point for re-drilling the subframe mounting holes -





Then I removed the rest of the rotten floor -





Then it was time to get the Deox Gel out -







So I give that a couple of hours to do its thing, and then agitated it with a wire brush and washed it off. I'm quite pleased with the results as this was well rusty.





There's still a small amount of rust in the pitted areas but I did apply some more gel which I'll get to later. So I decided to make a few pieces to repair the boot flange.

The places that needed repairing -







Rusty sections cut out -



Repair pieces -





Welded in and tidied up a bit, still needs more work which I'll finish next weekend. It's covered in Deox Gel in case anyone was wondering, forgot to take pictures before I applied this -







I've left it to soak in the gel overnight to remove the last bits of rust -



That's all I got done this weekend as the weather has been terrible, suns shining and then massive hail storms come from no where, British weather !!!

Edited by big-jay, 27 June 2014 - 11:02 AM.

[big-jay]

Parts update,

I've purchased two valance closing panels and a Heritage valance from M-Machine, they arrived today and I'm very happy with them.

Some pictures -









I wasn't to sure if the closing panels came with the strengthening panels already attached like the Heritage ones do but unfortunately they don't so I'll have to fab some up myself out of thicker gauge steel.

I'll be cracking on with this tomorrow, hopefully I'll get all the welding on the back end finished this weekend as I want to make a start on the passenger side.

[big-jay]

Update,

I've got quite a bit done today, the one corners now finished and there's not a lot left to do on the other. Here's some pictures of today's progress.

I started off by getting the closing plates in primer -



Then some black paint was applied -



Next I trimmed the boot repair piece, applied some zinc primer and fitted it into place with some inter grips -







Welded in and tidied up a bit, this Magnum panel is a terrible fit by the way, i know it an aftermarket panel and all but it's shocking how they can get away with it, will be the last Magnum panel I buy if I can help it -





Next I drilled the holes for the subframe bolts into the boot floor and made some stiffener plate -





You may notice it's short at the top but that's because some of the original strengthening plate is still in place and I wanted to keep it as there's nothing wrong with it.

Next I welded it all together -







I've still got a few pin holes to fill up and I'm not welding the hinge panel to the boot floor until the very end as I need to put the boot lid back on to check the fit and make sure everything's where i need it to be.

All in all not a bad days progress, will hopefully be getting this finished off tomorrow.

Edited by big-jay, 27 June 2014 - 11:05 AM.

[alex-95]

excellent work, the seats look great.

[big-jay]

excellent work, the seats look great.

Thanks a lot !

Edited by big-jay, 27 June 2014 - 11:06 AM.

[big-jay]

Update,

I've got the other closing panel fitted but didn't get chance to put the valance on as I had to paint and seal everything. Anyway here's some pictures of today's progress,

I made another strengthening piece and test fitted it to the car -



I then drilled the holes for plug welding and welded the closing panel on, it's not particularly pretty but it's strong -





Mocked the valance up and it fits beautifully -







Then I got the Nitromors out and stripped the paint from the whole area that's been repaired, never used this before but I'm quite impressed -









Then Etch Primed and Tiger Sealed -











That's it for today but may go outside and top coat it before work tomorrow. I will be stripping the rest of the underseal of the boot floor at some point as I want to use Dynax UB underneath the whole car.

I know my works nothing amazing but at least I'm having a go, I don't think I'm doing to badly for an amateur

Edited by big-jay, 30 March 2014 - 08:57 PM.

[Rocket.]

Very nice work

[Marco1972]

looking good son

Much better than it was before you now have metal where there was rust

Keep at it ..

[Minimoke8394]

Sweet dude. This is going to be one well sorted Mini when you're done. 

[Jacks]

Are those seats real leather and suede?
Or are they vinyl and suede?