Mini No.2, But From Scratch - Into The Unknown!

Projects Mini Saloons
1

After search for a shell for awhile, I can now finally start my complete rebuild project post on here.

So here we go, with the thanks to ‘simplyminis’ on here for the shell, here it is rolled into the garage:

Basically its a ‘P’ reg cooper, rolling shell, front and rear subframe, steering column, spi loom and a few others bits and bobs.

Shell is in good condition, only rust that needs work is one sill, and sorting the scuttle panel out, after the previous owner for some reason cut out the top dash rail

So I got cracking, Decided to clear it out and check all floor pans for rust (Nothing, except near the sill which needs replacing)

Then removed the front subframe, not the orginal subframe a old one, as it still has hub’s on the front.
So its now at the mo on bricks, but then made a crate with wheels, so I can move it around.

Rear subframe is causing a few problems, due to the nuts and bolts rusting and not budging abit, so Ive cut the two on one side out, the other side will be done tomorrow.

Heres a few more pictures so far:

Trying to plan the future for it, unsure what engine to go for, any ideas? I like a challenge but again Im a novice.

Thanks

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Sorry about the size of the first two pictures, I dont know whats happened there.

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I will be watching this one with great interest, welcome to the wonderfully expensive hobby of full resto

Good luck with it.

Paul.

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Yep goodbye money, hello restored mini

Love the look of that flipfront in your picture ‘junior mini’, thats what Ive got in mind something like that, but I know I’ll need all the help I can get, lol. All good fun tho

5

Been busy on it today, well doesnt feel much, but it has taken along time.

Got the rear subframe off, after cutting a number of bolts.
Then stripped it, but two bolts have snapped off in the subframe, didnt even turn them half a turn and ‘snap’, so thats annoyed me really.
Any ideas of what I can do? All I can think is weld a bolt ontop and try and get it out that way? *damn old rust - it makes easy jobs ten times harder*

Notice the two top nuts snapped off, and one on the side aswell. Any advise?

Cleaned the rear subframe up, afew areas of surface rust, but doesnt look major issue.

But I think the front subframe is going to be the problem one, so will have to keep an eye out for a new one maybe, we shall see. Anyone near wales got a front and maybe a rear subframe if I do need a new one?

Ciao for now

6

Bit of a update:

Sanded and rubbed down both front and rear subframe, decided to use rear subframe (aslong as I get the snapped bolts out ok) and I have brought a new front subframe (from Malvern show).

I have also brought a rebuilt gear box with hardy spicer connections from Malvern. Abit soon for gearbox on my project, but that will be stored untill its time.

few pics of front sub stripped and also painted in hammerite. I will be selling the orginal front subframe (as in pic), but without upper arm, lower arm, tie rod, or trumphets. It will be put on for sale section soon.

I have also started stripping the inside of shell regarding the loom. I believe its a SPI loom, so I have thought I’d remove the SPI loom, sell it, then replace with a older carb loom, as Im planning on puttin in a 1275 engine (will be modified tho). Can anyone suggest or forward me to what loom I can replace it with? or any advise?

I have taken out this yellow cable which lead to a box under the rear sits, I think it is maybe a airbag ecu? can anyone confirm this or tell me what exactly it is? will I need it?

Thats all for now, ciao

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yeah i think its for the airbag.
Good luck with the project!!

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Good luck man!
im currently learning bout minis so ill be watchin this topic see how stuf goes etc.
expect a few questions as im an annoyin lil’ bast

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> Good luck man!
im currently learning bout minis so ill be watchin this topic see how stuf goes etc.
expect a few questions as im an annoyin lil’ bast

Im in the same pond as you, learning as I am doing.

Ask away I say, loads of helpful people here willing to send you in the right direction.

Good luck aswell Barker!

10

Little bit of work today.

Stripped the old sub frame of suspension arms, and cleaned them up ready for the new subframe. Happy with the way they came up. So they are ready to paint.

But still havent decided what colour the mini is finally going to be, because I want to co-ordinate the subframes and everything with the colour of the car. So will have to think about final colour.

Also took out the steering rack, clean and sand that ready aswell, and also the steering column has been taken away and stored safetly.

And hopefully hearing from a guy this week about a engine.

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small update:

Got the spray gun and compressor out today to spray the suspension arms, and subframes. I have decided to go for a yellow and black colour theme in the engine bay and subframes.

And im still keeping up practicing the welding. Hope to try gas this week.

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Right update:

Done quite abit since last post. Flying along…

Got my welding going now, much easier using gas now.
So I cut off the out sill to reveal a few holes of rust, and also a few spot welds which I had to patch up.

Cleaned it all up, cut all the holes out, and cut some repair patches to be welded in place.
Using the U-POL no.8 primer i think it is, to cover the welds and to cover patches to weld through.

Then I got the replacement sill on, Went for the wide over sill panel. Got that seam welded on, also had to make a repair corner for just under the front wheel arch where the sill meets, Im not sure if you can see it in the pictures.

So here it is welded on and primed, I have also used seam seal everywhere I have welded to close it all up.

And then this afternoon I have finished the welding off near boot area, then slapped on abit of Hammerite underseal. I have left abit where the exhaust will come because I wasnt sure about the underseal and the heat from the exhaust. Anyone know if it is ok to cover that area??? I probably will be putting a exhaust protection plate (duno what it is called), that pins onto underside.

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Right another update:

The mini is now back on the crate with wheels, so the underside is all done and ready.

I then decided to chip off all the sound deadening stuff on the floor inside. I was suprised after putting it all in a bag how much it really weighed. So all that chipped off nicely with a chizel and hammer. Dont hit to hard tho!

I then seam sealed all areas which I thought needed a nice seam, let that dry and then covered in Hammerite no.1 rust beater. Making sure no rust comes back in future, and then primed it with Hammerite rust prevention primer. Again making doubly sure to keep the rust bug away. So it is now ready for painting inside.

NO its not pink its beige, lol, no my choice just the colour it came.

I have to weld a new upper dash rail on and maybe patch up scuttle panel or maybe replace it (panels are in post hopefully), once that is done then plans in order are:

Upper dash rail,
Scuttle panel,
Trim rear bins down, not much just the height slightly,
Rollcage (**I need one, anyone got one for sale? 6 point?**)
Re-build new subframes,
Put subframes on (plus wheels),
then prep for spraying,
Roof first (colour? secret! )
Then spray inside (colour? dont know yet)
Then body (colour? hmm )

thats the plan at mo, sure theres always other things popping up. Then engine plans and wiring loom plans

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looking good so far, you seem to have got on with it quite well
must have plenty of time and money

im doing the same but im hitting a bit of a dry spell with money,
might just haggle my boss for a payrise

keep us updated, i look forward to seeing it finished

do you know what colour your having it yet then?
if you do, dont tell anyone!!!
itll be awsome if you just went tadaaaa painted!

bish bash bosh

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Looks good mate what’s that running along the floor? battery, fuel cable?

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The cable you can see is the rear loom. It was like that when I got it, maybe tidy it up and put it inside the column.

But my plan is to have fuel and brake and battery lines inside. As Im going for the bare, rally look.

Ye luckily Ive got abit fo saved money to carry me on at mo, but trying to pick up the bargins first, as I know alot is going to be spent on the engine, and brakes probably.

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Update:

Thought I’d fancy abit of arm ache today so I decided to strip the paint off the roof ready to spray.

My first plan was to smooth the surface off and paint over, but after sanding there were a few pitts and scratches so I decided to take it all off.

Nitromors, electric drill and a paint remover wheel attachment = arm ache and bare metal roof.

Going to get the paint ordered tomorrow hopefully. And got a few nice suprises hopefully coming through the post this week

Just to make sure that my shopping list is correct:

Do I need: **Primer?**, **Paint?** - 2k? or celly?, **Lacquer?** (cant spell) and **Thinners?**

Sound right?

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Left roof now untill I get the paint and everything ordered.

Today I got a delivery of a few parts I need and one panel needed to finish off most of the welding. A new upper dash rail.

I have also patched up the scuttle panel, welding a small plate in, rather than replacing the whole scuttle.

So heres before and after:

Before: After:

I have also sprayed the inside now with stone chip, ready to be sprayed with 2k paint to give it a more solid finish inside as I think I am going for the bare look.

Hopefully start rebuilding the subframes up tomorrow if I get my deliveries through.

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Right havent posted on here for awhile so i will try and rem everything Ive done.

I have built up both subframes, havent got brakes fixed on yet, still looking for 7.5" set ups. The rear subframe in now built up and back on the shell, only for temp just too roll the shell up to garage for spraying.

When sanding the body work I found rust around the o/s headlight, which had been patched up before, but not very well, I really didnt want to replace the whole wing, a panel etc, so I decided to weld a new patch in, and I am happy with the result. Not quite the same shape but will shapen that when fitting head lights.

I also made a decision on whether to go smooth bumper front and back, or stay with bumpers. After along time if’ing about, I decide to go for it, so out come the angle grinder, and took off the front bumper and number plate bracket.
Wasnt too happy with rear tho, as I started on the o/s corner and worked across every 6 inches welding across aswell, but then came to the n/s and I cut off as much as I could, But due to the rear valance being put on terribly at an angle, it left me with one smooth side and a 4-5mm lip on the other side. So I have worked with filler to try and shapen and hid this lip, as I didnt want to replace the whole rear valance.
This shapening is still on going, but its coming.

So i then wheeled the shell up to garage where I have made a booth, using plastic sheeting, string, and a few bamboo sticks.

I brought all the paints, thinners, hardeners, paint, sandpaper, filler etc, that I needed.

So first things first I etch Primed the bare metal roof, after de greasing it first.

Then today I cleaned up and degreased the inside of the car, and the boot.

Then sprayed all with primer, on the roof I put on three layers (following the 21 page bible guide).

So thats it for now, I think Im remembered everything Ive done :S

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Just reat this thread and your doing a stirling job …keep up the good work…