390 replies to this topic

[Verderad]

Refitting the Clutch housing, would appear to be an easy job???

I thought that it had slipped on easily, slight gap at the bottom that I tried to pull with the bolts.

 

Loud bang

 

 

Cracked the housing, one of the bearing pins had come out, broke in half and was on the end of the shaft. 

Gutted, spent £40 having it vapour blasted.  

 

Couple of posts on Facebook looking for a replacement.  

 

Big Thank you to Ross Thomas of Thomas Classic and Modern for not only providing replacement but also fitting new bearings and then meeting in local services to deliver.  

 

More cleaning of parts 

 

Fitted new clutch, removed new clutch, rotated to align with markings - Read manual before not after.

 

Then I found this on the bench 

 

first time was just for practice. 

 

Progress 

 

I had fitted the Radiator but had to remove to get a socket on crank to turn engine for refitting distributor and adjusting the rocker gaps. 

 

 

Not sure if it needed any shims to make up the difference in flank thickness or if the gasket will deal with that

 

Then onto the carb.  Just a clean on the outside

 

 

Then decided on a quick look inside 

 

 

 

Full strip down and rebuild.  I can see many hours of adjustment to get it running correctly but that’s all part of the fun.  Then Call out AC Dodd.    Lost a morning to YouTube videos of tuning minis.  Very interesting. 
Realised that cleaning the needle with a green scotch brite to remove the crud has now probably ruined the needle.
Will fit the one that came with stage 1 kit and hope it runs 

 

Edited by Verderad, 13 May 2023 - 02:56 PM.

[Verderad]

Found these in a growing box of parts that I’ve bought and not fitted or maybe forgot I bought and ordered another. 

 

 

Which resulted in this 

 

Rebuilt both sides.  Its so much easier on a bench!!

 

Then fitted handbrake cables. 

Wow thats not a 5 minute job.  

Probably had 3 or 4 goes then Read manual.  

 

When your arms are not long enough to hold ratchet and screw driver 

 

More little bits fitted that you wont see

[Spherix]

Seeing your progress with washers, did you install the handbrake sealjng pad?

http://www.minispare...22.aspx|Back to

[Verderad]

I had some foam that I cut to shape. I also fitted the old plate on the underside but the other way around 

plates held in with bolts and lock nuts. 

Seeing your progress with washers, did you install the handbrake sealjng pad?

http://www.minispare...22.aspx|Back to

Edited by Verderad, 14 May 2023 - 07:34 AM.

[GT Jimmy]

Looking good, won't be long now

[Richard e]

I’d check the routing of brake pipes to the dwp valve: top m/c to left - or mines wrong- my brakes work fine - risk of locking up rear if reversed?

[Verderad]

I’d check the routing of brake pipes to the dwp valve: top m/c to left - or mines wrong- my brakes work fine - risk of locking up rear if reversed?

Thanks Richard. Will have to look in the manual.  It’s the same way round as it was when I stripped it. Checked the photos. However there have been one or two things that were not right.  

[Verderad]

I realised I’ve been putting this part off…..

 

Daughter there to turn the handle 

 

 

10 minutes of sticking subframe bolts to screwdrivers and hole alignment, engine in.

 

 

 

 

  Very pleased. 

Went so well when I realised I had not connected the heater take off to the bottom hose!!  I nearly took it back out

 

Getting bolt past the exhaust down pipe was a challenge 

 

What I haven’t got pictures of is the 50 times I got under the car, looked at bottom hose, got back out!!

 

routed in the electrics, wired in all except the front lights, new light lense to main harness needs to be made up.  That part is missing or attached to the flip front.  

Edited by Verderad, 22 June 2023 - 08:42 PM.

[colinf1]

You done very well to get the engine in with the downpipe and carb attached! 

 

On my clubman I lifted body over the engine/subframe combo, but on my current I lifted it in with hoist.

[Verderad]

Spent an hour getting car off the axel stands and beams back on to Axel stands to get exhaust pipe on. 

Had to remove the gear change to Turn the bolt that hols the bolt around to clear exhaust.

 

What is this bracket for?   It was on the down pipe

 

Then on to speedo. Strip and clean

 

All back together, new bulbs etc 

 

 

thank you @chris1275GT for the clips to hold the glass in place

 

Waiting on this to finish the assembly 

 

Onto the rest of the headlight wiring 

Solder on the new bullets 

 

Used the blow torch method

 

Create loom assembly 

 

Then fit headlamp bowls, but first spend 3 hours looking for the packet of screws 

side tracked into sorting draws of screws, bolts, machined screws etc 

still can’t find screws 

 

Starting to look like a clubman

Cant fit the offside side light,  really should have tried this when it wasn’t painted 

 

Drastic action, unfold 

but first heat with wife’s hairdryer 

 

Then fold back with mole grips and cardboard 

 

It worked!!  No cracking of paint 

Needs a little bit of dressing when I have a 2nd pair of hands 

 

Headlamp wired 

 

Not sure why it has the side light on the main build 

 

Got carried away with the side lights, cleaned off all the under seal  then cut off the wire and re-wired.

lost another half a day, that’s minis and the garage of lost time…..

 

Lense looks a bit shabby, I’ve ordered new ones (they don’t look much better!!)

 

Put the wheels on whilst i moved the axel stands, added the hub caps to see what it will look like 

 

Not sure about the old English white steels, looks like there are white walls on the tyres.   I think silver to match the stripes on the hub caps 

 

Thought the next job would be drive shafts, nice easy job!!!!  

I’m still cleaning grease from places I can hardly reach

[MrBounce]

That bracket is used as an exhaust steady bracket and attaches to the gearbox 

[colinf1]

There is another bracket that attaches to the diff output cover, it's here

https://www.minispar...gs/GEX7526.aspx

Edited by colinf1, 23 June 2023 - 04:31 PM.

[alex-95]

Great work, it's coming together very nicely!

 

Don't forget the split pins in the handbrake pins.

[TheBrownClubbyEstate]

Just spend a good few hours admiring this thread! Love the time and dedication folks on this forum put into working on these awesome little cars, and to then take the time to photograph, write up and share with us all! Hats. Off.

[Verderad]

Well this weekend didn't go as I wanted..

Only had to fit one drive shaft, bit of wiring and start the car......

 

Started with the clean jobs 

 

Fog light Switch 

Had to work out the wiring on bench before getting in the car. 

Needed a new earth lead, wired into the same one as the heater. 

 

Fit rear fog lamp 

but first deal with the couple of rust spots on back of bumper, treat and a bit of clear lacquer. 

fitted rear bumper, attached fog lamp. Drill hole in fresh paint of valance, fitted grommet

 

Fog lamp is an early 80's NOS cheapo £4 period item.. 

 

Switches fitted, will get new ones on order as they all look a little shabby. 

Lots more messing about with cleaning battery terminals, fitting grommets etc 

 

Then it was attach battery time......

 

Heater fan came on as battery terminals attached, thats one of the list.

Lights on, side lights ok, main bean took a while to come on??
Hazards - all working, flash a little slow

Indicators, left on, dash light on, not flashing. Right on, no dash light, not flashing.

Read forum, already read through many on Slow indicators.

Worked through the earths, added earth from indicator / side lights into loom, too much new paint for them to earth through body.
No joy.

Swapped hazard flasher and indicator flasher, better. Changed the connectors on indicator flasher.

Put bulb back into dash indicator light!!

 

Still not flashing

Changed bulb that didn't have any markings on.  Flashing !!!

 

Whilst lookin at the forum there was a suggestion that changing the bimetalic flasher for modern is a better solution. I have one of those from an incorrect purchase.    Needed another earth lead but the flash is now very consistent and brighter.   Ordered another unit to replace the hazard flasher.  

 

Lights all good, main beam really slow to come on?

 

Checked all earths, some not a tight in new connectors, quick squeeze with the pliers.  

 

Then I noticed the main earth onto bulkhead was not tight, bolt not doing up tight, thread in bolt knackered.  

Tapped out to 8mm.  Amazing difference.  

 

Brake lights staying on. 

Not enough adjustment to move the switch back far enough. 

 

screw added, now works fine. 

 

Onto the heater plumbing.   Why is it that the outlet on the heater matrix is in the wrong side?  

Having fitted the heater, decided the best option was to remove and rotate the matrix.

New holes 

 

 

Plumbed in