As usual with this car, I had some set backs I didn't expect! But they're sorted now.
Firstly I finished off all the jobs underneath the car, main one was rubbing down under the boot floor. So that got a good rub down, a few spots needed wire brushing to remove some surface rust, then was treated with hydrate 80, a coat of hammerite and once that was all dry, it all got a coat of underseal. Once that was done I wanted to waxoyl everywhere that needs it on the car - Easier said than done trying to get waxoyl to flow and spray nicely when its cold :/ Ended up thinning it 50/50 with whitespirit, sitting the can in boiling water for 30 mins before spraying, and then putting it in fresh boiling water whilst spraying; even then it wasn't spraying in a decent 360 pattern like it should out of the extension probe but it was good enough.
Everywhere got done with the waxoyl, all round the subframes and crevices and gaps between the shell, rear valance box sections, sills, scuttle closers inside and out, inside the doors, door posts and then inside the bulkhead crossmember and behind where i've has the shock mounts repaired. So for rust proofing its sorted - Although because the waxoyl was thinned so much with white spirit I was basically high on vapours whilst doing this and it took about 3 days to air the garage out!
Once that done I fitted all the fresh air vent ducts and intake for the heater etc and got the car back on its wheels and off the stands. I was then going round the car checking everything mechanical before I got carried away with shiney bits and interior - Good job I did as I found some play in the rear drivers wheel bearing. So then set about fixing that and found the adjuster on the drum was seized solid! It was stiff before but did move, I guess I should of took it apart and greased it then before it had chance to seize in. I tried for ages to free it, tried penetrating oil, blowtorch/quenching the adjuster to try and free it off but nothing worked and after a while the adjuster rounded off
So I took it all apart and it was no wonder it was seized really once I had a proper look at the backplate:
Psssshh - So new backplates and adjusters were bought from minisport for both sides, just those bits as the shoes and cylinders didn't look that old. Built up the new backplate and fitted the drivers side, went round to the passenger side and find the shoes on that sides were much more worn, 2mm shoe material left max and the cylinder was seeping fluid a bit
Basically should of just gone all out and bought all new back brakes in the first place. Went off to moss and got new cylinders and shoes for both sides, and also got a set of extended goodridge braided hoses as the standard rubber ones looked shabby and the cooper unions were seized on when I took them off.So ended up replacing the rear brakes completely, only bits I reused were the handbrake levers as they just needed a clean up. But at least now the minis got new brakes and braided brake hoses all round, so should be nice once bedded in and the hoses will give me nice pedal feel too. Just need to remember everythings new the first time I drive it as I won't be stopping in a hurry!
After that I spent a while adjusting the clutch as it didn't feel right at all. Ended up giving it a quick bleed, didn't see any air in it so I think it was all down to the adjustment. I then adjusted the stop nut on the clutch arm to below the gap it says in the hanyes and the clutch felt spot on after that. So slapped the drivers seat in and reversed it out of the garage - Was the first time its moved under its own power since the new engine got put it
But the clutch feels good and gearbox worked ok in 1st and reverse at least so thats good!
Last couple of bits finished in the engine bay, washer bottle in, wiper motor polished up and strapped down, washer jets fitted and plumbed, wipers put on too. I ditched the bit fresh air scoop for the heater since it takes up half the engine bay and looks poo while its at it. Instead drilled a couple of holes in the inner wing and cable tied the pipe to the wing. That way its still gona get fresh air but its just not in the way.
Engine/bulkhead could still do with a wipe down and shiny bits a polish but that can wait.
Moving onto the interior I had a few bits to wire. Cig lighter re-wired to my new fusebox, oil pressure/water temp gauge wired into the sidelights so thats illuminated at night, warning light for the fuel pump too so I know if the inertia switch has been tripped. The radio/speakers/amps install i'm going to leave till a later date because i've changed my mind again about that lol But put the basic wiring in place from the fuse box into the car to put the radio in later. Also fitted a toggle switch to the fuel pump feed so the fuel pumps not constantly on if i'm just sat with engine off/ignition on listening to the radio of something. I put the switch in the lower dashrail where the heater cable would of been so its nice and neat.
Then fitted the rear view mirror, sun visors and trimmed the last bits of excess off the headlining and since the car was back on its wheels I could move it over in the garage enough to get the passenger door open and the central locking wiring routed through into the car. So that was the last job that needed doing before the door cards could go on.
Since with these streetfighter doors, all the water that hits the window drains into the doors and since the inner door is cut away it all comes into contact with the back of the doorcard. So I used some old roofing damp proof course stuff for this. Cut it to shape and stuck it to the back of the door cards with double sides vinyl flooring tape which was really strong, and then went round the edges with duck tape to finish it off. I left an inch overlap at the bottom that I could tuck into the bottom of the door, so all the water drains off into the door and not into the car:
Then got them fitted to the car! I used rivnuts to screw the lock surround into since the door cards were so thick. They weren't the best fit in the world these door cards and it didn't help that the plastic clips take so much force to pop them into the holes in the doors, because the inner door is cut away, the metal just flexed before they'd pop in. So the bottom of the door card isn't actually clipped in, but the rest of the clips are in and the handles hold it in place anyway so its not going anywhere:
Happy with those
After that I spent a full day with a mate giving the car a proper wax, polish and wax. Spent the whole day on it and even then didn't get round to cleaning the glass!
But it was worth it! We used autoglym ultradeep shine polish for most of the car, and paint renovator for the scratches and swirl marks. Most of which are gone now, just the odd ones that aren't worth the effort remain. Polished all the chrome with autosol, sealed the wheels with autoglym wheel sealer an shined the tyres too. Then we gave it a coat of autoglym HD wax which really brought out nice shine and reflections, the paint feels like glass now and this wax pot wouldn't even stay put on the roof, just kept sliding off!
The paint isn't all perfection though, theres a few spots of the micro blistering coming back through the paint again - Don't know what a bodyshops problem is with going to bare metal when i've asked them to. Obviously think I don't know what i'm talking about. But i'm just past caring now about the paint, its shined up nice for the most part, but next paintwork it needs doing i'll be doing it myself!
Then got the back seats and wheel arch covers in place, fitted the new seatbelts and refitted my harness on the drivers side. I'm leaving the carpets out for now as i've still got a water leak problem - Its the sliding windows, think I cut the seals a couple of mill too short when I first fitted them, but obviously 2mm is a lot when you trying to seal out water! But it'll do for now and i'll get some more of the sliding window rubber stuff and re-do them at some point once the cars back at home.
So basically thats the interior for now. Parcel shelf is staying out until I decide where i'm mounting my speakers, and just need to make a new base piece to go on the lower dashrail to meet with the dash lining to finish off the dash. That'll just be wood covered carpet slotted into place when its done. The heater hoses are a bit long too so i'll trim them a bit at some point so they're not dangling down so much:
Then it was time for the shiny bits on the outside, last finished touches
Mirrors on and adjusted, grill moustache is fitted with rivnuts, so officially no self tappers going into the bodywork aside the numberplates because I ran out of rivnuts and grill just on grill buttons again. Spotlights on and wired up and working nice - Forgot how bright they are - The heat they give off is immense! Numberplates on and the finishing touch - Exposed weave carbon bumpers
So for now its finished!
Tomorrow will consist of ringing round insurance companies to find the best agreed value quote, then ringing round seeing who will do me an MOT the quickest! I'm starting a new job on 13th of June so i'm hoping to get the mini on the road so I can get some driving in it before I start working again
Edited by mike., 06 June 2012 - 12:05 AM.
