168 replies to this topic

[dezshearer]

Hey there guys, i've been posting my project on my local club website.. but i figured i'd post on here too seeing as its more active!

I bought a '95 Mini Cooper in November (Nov 11th 07) and have been working at it slowly since then.

It's an automatic, and the body work was in an okay condition, just a few bits of rust and dented sills (from jacking i think)

However, it was a non runner.















I eventually got the car into the garage, after a massive clear out! and had the car up on a huge plank of wood to make access a bit easier (when i discovered the huge dented sills, i get some pics of that later =(





I've decided to drop the entire front subframe out, which i'll do this weekend.

I had started to remove parts to just take out the engine originally, following my haynes manual, but i figured, seeing as i need a new engine, and pretty much lots of other bits for the convsersion to manual, i'll just strip the whole car!

I then had to look for a replacement engine, and i came across as 1300cc a series from a Morris Marina, it COULD work... i thought i could use some parts from the auto engine, but i was terribly wrong!



So, long story short, trying to use an in-line engine when you need a transverse is more trouble than its worth. I stripped it all down though, and cleaned it up ! Learnt quite a bit, but wasted time money on the cleaning! I'm having the cylinder head reconditioned though, then i'll sell it on.



While cleaning/painting the un-usable engine, i painted my radiator just to be different, i think it looks awesome, and will match the nice red engine when it goes in!


Anyway, i've managed to source a new engine, a 1300cc block with omega pistons, sw5 cam, centre main strap, reground crank and fully balanced!

[no pics of the new block yet though]

Anyway, i've got loads of pics here

http://www.flickr.co...57602839365924/

I'll keep you guys posted on updates!

Oh and by the way it's got aircon! its a jap import! Don't know if i can put the aircon back in in the rebuild, some of the parts are damaged!

Also, im stripping out the interior, completely! I'm planning on keeping the body black though, with the white roof and stripes!

P.S. i bought a locking wheel nut remover tool from laser, but neither of the sockets fit, too big.. i need to find a smaller one... or doe anyone else have any tips for removing locknuts (without the key )

[mk1leg]

Nice Mini and be carefull as autos are very tricky to strip down loads of very small parts ..................good luck and keep us up dated............

[dezshearer]

A tiny tiny update!

First off, i grinded my cylinder head at my night class in the tech. Dunno if keep it and use it, probably just sell it on after reconditioning it, anyone know how much they sell for?



I also got my new engine block today!

I'm also gettin' a lightened/balanced flywheel and clutch!



Block Specs:

1300cc
11 Stud
Omega Pistons
SW5 Cam
Centre Main Strap
Reground Crank

What sort of cylinder head should i put on this thing? and anyone got any advice on rocker rollers etc?

And after all this madness, i tidyed up my "workshop", the messyness from dismantling that first engine, and doing other thing was really doing my head in, and i finally bodged up a "work bench" of sorts!

[clubby]

hye mate.. u have great mini ~! CONGRAT

[dezshearer]

Update!

First off, it turns out my new engine block is a 1330cc not 1300.

I'm gonna get a new head for it, with 1.5 rockets and drilled for 11 stud head, might go up to stage 2 or 3, may aswell considering the quality of the block!

I got LOADS of help from 2 local club members! They're great blokes! They pretty much removed the engine and subframe for me last nite, i couldn't have done it without them.

Engine + Subframe:

I need to strip the steering brackets/radius arms etc, all those wheel turny bits and get the cleaned, then sandblasted.

I also have a new subframe to get sandblasted, then im painting it a nice shiney red!



Engineless:


Floor isn't to bad conditon! Took out the passenger seat for better access!



Hole in the sill! i hate the rust fairys:


Steering Column, need to strip it, remove any shitty wiring that was left from the imobiliser, clean and repaint the column, fit a new igniton column, and generally just tidy it all up! might cover the housing in black vynal!

[dezshearer]

Well, got the new front subframe back from the sandblasters today, and its in great condition, so gave it a blast of red hammerite to test the colour!



I thought it was awesome, so about 15 mins later....



Thats only the first coat, and its got some runs =( im gonna sand it down and respray a couple more times, nice smooth, deep finish.

Also, decided to go flipfront, unsure about steel/fibreglass right now.. but the front wing has come off anyway =)





I'll cut the rest of her off tomorrow, then tidy up the engine bay! then clean it/repaint it.

I also ordered some parts today.

Rear Rollcage
Full Scuttle Panel to replace my rotten one
Solid front subframe mounts
Suspension mounts
Steering Rack
Ball Joint Splitter
Aeroquip Oil Transfer hose

and a few others bits n pieces, cant remember off the top of my head.

I need to go exploring for more rust to see what else needs replaced, got a paint and rust removal disk for the drill, so we'll see how that goes, wish me luck!!

[VulcanBomber]

Looking good, is that a Jap import car? Its just I saw the AC unit, and its someting I am looking at for the near future.

[dezshearer]

Ooo sharp eyes! Yup it is indeed. It had air-con, pretty sure it works, but unsure, needs a new radiator/condenser for the aircon and new plumbing.

I'll probably put it back into the car once i have it running and the bodywork/interior sorted.

But unsure at the moment.

Just discovered a LOAD of rust under my dash.

The Inner Dash rail is completely gone, and so is the scuttle.

[dezshearer]

No updates recently as i'm waiting on parts from MiniSport still. Sigh!

I'm pretty sure i need new sills, and maybe new floorpans.

So the bits i need to replace are:

Scuttle
Inner Dash Rail
Sills
Floorpans(Poss)

Then theres some steel to weld in for patches:

Hole in the boot
Top shock mounts on the bulkhead
Hole on the rear arch
Anything else i find =(

Which order should i do these in? Whats the best way to go about it?

I'm sending the cylinder head away to MED Engineering to get it up to Phase 3. And i've started to strip the engine block, i'm going to get everything out of it then send it to a local engineers to get cleaned up, no skimming or anything, just a dip in whatever chemicals they have!

I'm slowly stripping out all the guff left in the engine bay, and once i get the aircon out it's going straight into storage! That'll be a project for when the cars actually up and running.

I got some parts of a local mini that crashed:

Master Clutch Cylinder
Clutch slave cylinder
cluth pedal and brake pedal
Brake master cylinder/servo and brake slave/bias thingie


And then i got some bits from a guy in my local club.

LCB minus the y-piece but for 10 quid, i'm not complaining

1.75 MG Carb with alloy manifold and K&N Filter


Gear Change

[clubby]

hye mate.. great job.. keep it up

[dezshearer]

hey guys!

The weather was fantastic today so i got out into the garage when i got home from uni!

I'll let the pics do most of the talking, but i stripped out the interior and attacked the bottom of the sills with a wire brush on the angle grinder.

And then towards the end, i was gonnna take the rear sub frame off, so i started to undo the petrol tank.. and you'll see what i found from the pics...

The holes in the floor/sill from inside...


Looking from the outside, i need to get that beam out of the way to get at it more..



Better shot of my scuttle/inner dash rail, what a mess:


It's the same at the other side...well, worse to be honest, especially the inner rail:


Stripped out interior:


Stuff:


This is what i found behind my petrol tank, he was pretty big!


plenty of grinding and welding to do enh?

[Cliolord]

plenty of grinding and welding to do enh?

Similar to mine Good work mate, Mini's look awsome in black!

[dezshearer]

How about a long awaited (yeh right!) update?

First things first.. i needed to build something to hold the body shell while i do repairs to it! so once the rear subby comes outs, the shell will be sitting on this masterpiece!







Even has a TEA HOLDER! Very Important!!



Heres some bits and pieces i've purchased!



Wee repair i did! With pictured kit!



Refurbed subframes:



Someone had welded them shut, so that they wouldnt slide, so i fixed that issue with the grinder, then resprayed them!

Genuine Inner Dash Rail and Scuttle, fit a treat!



Non-Gen flitch panels, floor pans and underscuttle bits! The other floor pan is with the car atm.



Recent Work:

Stripped and cleaned the 1330 Block:



Cleaned up the omega pistons a bit:





Painted the new shock mounts:



Bulkhead is pretty much stripped, cant get the clutch/brake cylinder plate off cus the bolts are rounded and rusted. grinder time soon!



Drivers flitch removed, floor will be next, can't weld new flitch in cus the floor thats there is all bent in from jacking =(



Scuttle and inner dash rail removed, plenty of patching to do to top of bulkhead.





Worst part of the bulkhead:



Waiting to be offered up:



Part of my new dash... possible idea:



I plan on covering my new blank dash (plain mdf) lol in checker plate, then putting it straight down to the ground with that checkerplate panel! So i'll be replacing all the switchs and with nicer onces, and having dials with black faces. Push button start too!

I'm going to "hide" the choke cable near the drivers door, coming from under the dash, towards the floor, that way, only i can see it.

Also, removing back seats, carpeting over them, checkerplate rear parcel shelf to match the front dash!

Also decided im going to run the fuel lines and brake line internally, anyone got any advice on this?

On the internal side of things too, i'm putting as much of the new wiring loom as possible inside the car, i want hardly anything outside, so i'll be mounting the fuse box is a snazzy see through box on the dash, easier access etc.

The car will look pretty stripped out, still have carpets though !

And finally, i found an electric demister on a kit car site, thinking about using it instead of the heater..

Anyone know of any good alternatives to the mini heater? or should i just keep it?

[dezshearer]

No one seems to care!

But here's an update anyway:

Here's an update!

Yesterday i removed the rear subframe!

6 out of 8 of the bolts needed to be dremeled out!



Tack Welded in the new drivers floor, my welding is pretty shoddy i think, but it's getting better!



Bulkhead lip Repairs:

I'm going to redo these, the metal is soo thin to weld too, so, im going to cut out bigger sections so i can weld to the thicker metal, then just grind it thinner at the top.

So yeh, pretty much a practice repair, what do you think?

[Mayfair85]

Looks like your doing a good job mate! Did you change the front subby?