Keith's & Paul's Builds

[substitute]

Hi everyone, another couple of converts...

Having been inspired by SpNOam's excellent conversion at Castle Combe in September 2008, (and in this month's press!) I have since acquired the basic bits of kit I think I need. This includes the rather late discovery in the MiniWorld Ads of a part converted mk3 mini 'unfinished project' already fitted-out with a home-brew subframe and engine and a number of boxes of bits; wiring loom, manifolds etc. Even so, some serious effort is obviously needed to finish off!

I am now ready to commence my conversion in February this year as is my fellow club member, Paul, alongside it so we can both problem-solve and work together (using the project car as a start guide).

I currently run a self-modified 1330 turbo (102bhp/109lbs/ft) in my '66 modified shell (mini magazine - Jan'99 ;) so this is the 'next incarnation' of it.

Paul's is a '63 Morris Mini Minor Super Deluxe which is currently being stripped back for some essential body repairs.

We look forward to regularly posting our progress on the forum.

We will have problems but, happily, there is a mine of info on here...

Keith & Paul

These are our project minis...

The Blue One...Unfinished Project Some work to do :rolleyes:
http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/The%20Project%20Minis/IMAG0056.jpg

The Red One... 1330 Turbo (15psi) :cool:
http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/The%20Project%20Minis/KeithsMini.jpg

The Green One... The (future) Wolf :D
http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/The%20Project%20Minis/barbarmini003.jpg

[miniswift]

Hi,

Welcome guys.
I have started mine long time ago and still doing it!
If I can help you in anyway, I will let you know.

Cheers
Atchi

[Andy_S]

Welcome to the dark side :twisted:

[substitute]

Thanks Atchi, any and all help will be most welcome along the way.
Andy, How dark will it get? :D
K'n'P

[miniswift]

We haven't heard anything for a while from you boys!
Any progress?

Cheers
Atchi

[substitute]

Hi Atchi - thanks for the nudge :)
Been 'distracted' with a number of things (but no excuses eh?!)
The Green One: Now in bits and boxed up ready for full body restoration
The Red One: Had to replace turbo (lunched itself) and an in process of adding intercooler (ready for Castle Combe Action Day).
The Blue One: This will be the first on the road. Needs some repair work - still in storage (a fair distance away).

We have just got confirmation of a 'hobby' workshop to rent (shared by 3 of us) 10m x 10m from this month (Sep.10) can collect everything together in one place and get busy over the winter. Looking forward to getting on with them with more space than a crowded unheated garage to work in :)

Been looking at this biva issue of late. No question it is a bit of a worry (who wants a Q plate on a classic 'shell?) but no one seems to have any definative answers - very frustrating.

[Joah]

Ah a fellow oxfordshire member! :) only just come across this but remember seeing the red one about, part of AMOC aint you? I really need to do the same with a workshop but my missus would hate it as I would permenantly be there!

[substitute]

Hi Joah,
Absolutely right (AMOC Club Treasurer).
Also right on the workshop front. My missus was not best pleased but is over it now ;) - even said she may have to bring sunday dinners over to me... result or what!? :D
Have a way to go with these 3 but it is about time they are blessed with the modern engines BL/ARG should have got around to doing a long time ago. My turbo A-series is about as far as is possible to go balancing performance and reliability (for IMM round trip every year especialy) +++ you get a 5 speed tranny out of the deal... sweet :)

[substitute]

Update at long last...!

Blue is now a bare shell we have had a couple of weekends 'on a mission' after signing up for IMM2012.

More tin-worm found than expected. fresh tin to order this week.

No going back now - a good thing :)

[substitute]

Another Update...

Working hard on the Blue One - Hungary IMM2012 is looming ever closer!!!

The subframe it came with was badly engineered; No box sections, no triangulation... No confidence in it. Acquired an Allspeed fabrication and a 'spare' shell to use for dry-fit etc. while the repaired body (Welding by Andy Butcher), currently close to completion for Paint, is progressed elsewhere.

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/The%20Blue%20Build/SAM_0536.jpg

We have the unit sat in the Allspeed subframe in the spare 'shell so close to sorting out the fit :cool:

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/The%20Blue%20Build/The%20AllSpeed%20Subframe/SAM_0343.jpg

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/The%20Blue%20Build/Engine%20Dry%20Fit/SAM_0512.jpg

Looking through the various builds to try and work out why it is sitting a bit high so we can ease it into a sensible/recognisable position in the engine bay on the weekend.

The Inlet Manifold is fouling on the bulkhead (standard)

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/The%20Blue%20Build/Engine%20Dry%20Fit/SAM_0511.jpg

I remember reading the Mk1 Inlet Manifold is a better fit (?). I have a spare and it is in to be shortened by 25mm (Thanks Rob Walker). I won't mind a little local reshaping of the bulkhead on the Blue One but would like to solve the problem before pitching into the conversion of the Green One (MK 1) as we don't want to compromise the original shell if possible.

Comments on the above issues would be very welcome at the moment... every weekend and evening counts.

My Photobucket Album Links:
Bodywork: http://s697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/The%20Blue%20Build/
Subframe: http://s697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/The%20Blue%20Build/The%20AllSpeed%20Subframe/
Dry Fit: http://s697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/The%20Blue%20Build/Engine%20Dry%20Fit/


Cheers All :D

[substitute]

Decided to have the bulkhead modified to provide more manifold room on The Blue One (upside).

This has removed the holes for the Master Cylinders (Downside).

Cunning plan is to Reverse copy an original dual control kit (Discovered by Paul on eBay - Double Stroke of Luck as my Lad is learning to drive) so the Masters are on the Passenger side.

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/The%20Blue%20Build/DualControls.jpg

Another drawing to do ;)

[Birdman]

Yes, that is what I look at doing a while back with HE-MAN dual controls. If you use two mini pedal boxes and modify the drivers side clutch pedal to have a seperate pivot, you can then run a shaft across under the dash to conect to the other pedal box for the braking. In the end I ran out of space so didn't bother.

[substitute]

Bought a 1986 Honda CRX today ONE owner!!, low mileage FSH and a 1.6 that revs freely and doesn't smoke at all. NSF wing (plastic) shattered and bodywork pretty much pants. Overall though an unexpected Total Result :D

http://s697.photobucket.com/albums/vv339/RedMin/Honda%20CRX/

Will tuck it up for next year's next project... a bit busy at the moment as The Green One is finally off for welding in 2 or 3 weeks so we have more space in the workshop to put together The Blue One for IMM 2012 - Hungary :cool:

[Purtsi]

I'll come and check your Mini at Balatonfüred then ;-)

[spNOam]

You either have to use all MK1 bits or all MK2 bits, that is if your using the swift ecu, it won't like it otherwise. You can probably get it to work with a mix and match but it'll be loads of hassle.
MK1 fits with no bulkhead mods :) MK2 no such luck :( but its only a small mod.

[substitute]

MK1 fits with no bulkhead mods :) MK2 no such luck :( but its only a small mod.

Fitted the Shortened Mk2 Manifold yesterday. The 25mm chop did the job, reasonable clearance achieved plus the inlet tubes still line up with the inlet flange :D - wouldn't want to go any shorter though...

[substitute]

I'll come and check your Mini at Balatonfüred then ;-)

Look forward to it :cool:

[substitute]

Welding and bodywork finished (I hope!).

Bodyshell delivered to paintshop this afternoon... :D

[KMG]

I'll come and check your Mini at Balatonfüred then ;-)

Me too,I hope to have mine finished in time for Italy 2013 but then again I said that about Germany 2010 :oops:

[substitute]

Me too,I hope to have mine finished in time for Italy 2013 but then again I said that about Germany 2010 :oops:

The Green One is to be finished for IMM2013 Italy - We're starting a bit earlier in the year with it so more time for the build and, hopefully, all niggles will be sorted out on The Blue One.

See you in Italy :D

[SPOONS]

Fitted the Shortened Mk2 Manifold yesterday. The 25mm chop did the job, reasonable clearance achieved plus the inlet tubes still line up with the inlet flange :D - wouldn't want to go any shorter though...

Hi, your progress is impressive, well done.

I'm struggling to get the hours in on mine with working rubbish shifts.....quick question though if you don't mind. I'm interested how you got the Mk2 inlet manifold to fit without modding the bulkhead, where was it shortened and how. Any pics?

[substitute]

Hi, your progress is impressive, well done.

I'm struggling to get the hours in on mine with working rubbish shifts.....quick question though if you don't mind. I'm interested how you got the Mk2 inlet manifold to fit without modding the bulkhead, where was it shortened and how. Any pics?

Thanks Spoons - nice compliment... took us a while to get organised now we're going for it big style :)

Time is always a defining issue - read any build diary... Hi Atchi :)

The inlet manifold had 25mm milled out just back from the rear of the flange. This seems a maximum as the ram pipes are still a close enough alignment to re-weld and grind flush on the inside with sufficient to prep and weld to left on the manifold flange. I am pleased with the final fit as it doesn't foul anything :D To move the engine over the last 20mm or so I plan to 'gently' concave the vertical part of the bulkhead in front of the pedal box & behind the manifold with a BIG hammer ;) Should work!

[substitute]

We are Collecting The Blue One from the Painshopthis Saturday! :D

[substitute]

After 2 Weekends just 'Organising' we are ready to Assemble.

Collection Day

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/SAM_0693.jpg

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/SAM_0702.jpg

In Workshop

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/SAM_0703.jpg

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/SAM_0708.jpg

My Full Size Haynes Manual

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/SAM_0705.jpg

Also, having the engine mount brackets remade to my own pattern the Suzuki Sits much better in the standard (dry fit) shell :D

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/The%20Blue%20Build/Engine%20Dry%20Fit/SAM_0724.jpg

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/The%20Blue%20Build/Engine%20Dry%20Fit/SAM_0732.jpg

More available in my Photobucket ;) - use previous links

[Purtsi]

That looks good, really good. Keep up the good work :)

[substitute]

That looks good, really good. Keep up the good work :)

Thanks for encouragement.
Trying to crack on but dealing with the very welcome arrival of work!
Some balancing to do.
Big weekend coming up... Probably 2 :-)

[Marcus Nordblom]

shell looks great!

[substitute]

shell looks great!

Thanks Marcus. Paint feels like warm water when you touch it.

[substitute]

Hi Guys,

Very busy but fruitfull weekend. Minitastic Fast-Road progressive spring kit arrived Saturday morning with the Gaz Shox so finished the Subframe build and installed today - Getting into place was the usual pinch, poke and lever operation taking an hour or so but we're on at least one pair of wheels now! :D. Pedal box had to be slightly modified to suit bulkhead 'easing' and needed a little encouragement to fit. Mini Wiring loom in from rear to front... I have both the Suzuki GTi and Mini front looms at home to lay out on the kitchen floor and see how they stitch together (Mr. Popular!). Working towards Front End where it will all be happening. A few evenings and a (very) long Bank Holiday now planned - After all,we're leaving for the IMM in Hungary in just a smidge over 3 Weeks... Argggggggggg! :rolleyes:
A couple of quick pics pending full Photobucket upload.

[STELIOS_]

lovely

[STELIOS_]

mine

[substitute]

Nice one. Strangly familiar ;-)
Working hard to get ours running and ready for Balatonfured.
Good weekend coming up!

[arterz]

I know that guy, he is a good friend, he built a g13b mini very well, I'll try to take some more pics if you want

good progress Substitute :)

[substitute]

Ready to go down to our workshop for the first of 3 intense build days :D

Will try and keep a record of each day and post regularly. Fully prepared with a box of :beer: and just printed my GTi wiring diagram off at 2x full size to put on the wall.

Looms had to be removed from the kitchen floor (no work around apparently LoL) and are now back in the workshop laid out ready for surgery.

Subframe is now fully welded. Driveshafts are measured and with the machine shop to be modified (back Wednesday).

My full size Haynes Manual is much smaller and our Mini GTs (imagine the Mini GT badge with a smooth type small Suzuki 'S' under the T) is starting to take shape quite quickly.

More updates throughout the Weekend :cool:

[substitute]

I know that guy, he is a good friend, he built a g13b mini very well, I'll try to take some more pics if you want

good progress Substitute :)

Thanks Arterz. Would be nice to see a solution (from anyone) for a hydraulic clutch actuator using the Mini verto type slave cylinder - read it somewhere but can't find the post so know it is possible.

Cheers.

[Purtsi]

Does this image help at all? Not my mini though..

http://kuva1.kuvablogi.com/iso/img3465069.jpg

[substitute]

Thanks Purtsi - Ideal. :-)

Decided to go with full Suzuki loom. Everything tagged so I know what can be culled or kept. Modification in the slot for tomorrow.

Early start, long day.

[substitute]

Bit of a steady day yesterday. mainly Labelling the Loom off my diagram.

Surgery starts today. Should go from A floor loom :confused:

to A fully fitted bespoke one by end of today!

[substitute]

After a productive couple of days the Suzuki Loom is now modified for the Mini :)

Saturday was spent laying out the Loom and tagging up with just a little planning as to how it ought to go in the Mini. It is a big gangly thing!

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120505_095638-1.jpg

The Bare Dash
http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120505_095727.jpg

By the end of Saturday we had the loom assembled on the floor and fully Labelled.
http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120505_172642.jpg

Surgery started in earnest on Sunday morning after an hour spent labelling a Second Loom (for the Green One) off the other.

The Loom was fully opened up and clipped with 'Cable Tidy' so redundant wiring could be removed; Rear Wash Wipe, Power windows, mirrors, AirCon Connections etc. and rerouted where needed; Courtesy light ground wires, fuel pump etc.
The individual bits were then loosely placed in location in the shell to imitate the Mini Wiring Loom routes:

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120506_225059.jpg

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120506_225237.jpg

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120506_225043.jpg

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120506_225259.jpg

There is, inevitably, a big loop of wire to be lost on the cross-dash loom section. However, as departure for our trip to Balatonfured is at Tee-Minus 15 days I will leave it looped under the dash!

A tidying mod was made to bring the W/G 30A feed into the Fuse/Relay Box and also a controller block (function unknown..!). the main fuse strip was cut to remove the spare fuse position and the 30A feed inserted (Yellow Tab). The block is relay sized (but not a relay?) so this was located in one of the spaces reserved for Aircon (Green Tab).

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/IMG_20120506_191358.jpg

A couple of good days which were not without their cost!...

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120506_225549.jpg

More pictures on my Photobucket Album - http://s697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/

[substitute]

Paul and myself spent a productive day at the workshop today'

Paul cracked on with a cleaning mission. everthing that looked in need of tidying up was given the full treatment; wiper Motor and drive, front Shock mounts etc. His Piece de resistance is without doubt the Cam Cover. Cleaned in the Blasting Cabinet (Thanks to our mate Dicky) followed by a couple of coats of etch primer then numerous mist coats of gloss - beat my attempt at Hammeriting it and the not-so cool Niagara Falls of runs that resulted! Good Job :) No picture of his artwork tonight as Paul took those.

For me it was also a mission today but on the wiring side. yesterday everything was starting to drop into place. Today it was pretty similar... Managed to get the loom sections properly into the mini shell. The Instrument Pod had to be raised a little to fit the bulkhead blanker plate. Fortuitously, this created a tad more room underneath and to the rear.

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120507_185554.jpg

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120507_185622.jpg

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120507_185537.jpg

The surplus of cable was fold-looped across the dash to narrow (no time to risk a bad connection by shortening off!). The plugs, connections to the fuses and routes to the rear and front of the Mini are now complete.

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120507_185615.jpg

This has left just the location of the Main fuse + Relay Box to sort out. as I have no convenient engine to hang in place it was sensible to elect to leave the task of final positioning until Wednesday evening when the Subframe & Engine are returned... complete with a couple of willing helpers to assemble the doors, fit the headliner, rear 1/4s and glass.

As ever - more on my photobucket - see earlier link.

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120507_185930.jpg

Will be driving it VERY soon :D :cool:

[substitute]

Another blinding evening in the workshop.

Subframe and Engine returned so ready for the first fit into The Blue One. Bolted the Re-Engineered Standard Subframe in place and assembled the hubs (no driveshafts yet :( ) top & bottom arms with tie bars. Looking good so far. Engine crane to lift the G13B into place with the Inlet and Exhaust manifolds fitted. exhaust Manifold fouled the front cross bar (A standard cast Ex man would probably be fine). Unbolted and left loose. Engine dropped in like a dream and the Ex-Manifold needed only a little persuasion to fall into place and be bolted.

So far so good :)

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120509_195229.jpg

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120509_195238.jpg

Once we were happy with the general engine position the front end was retrieved and carefully fitted around the engine. The relocated tie bar mounts now bought the bar ends into contact with the valance panel. I elected to trim the excess thread off the tie bar end (about 10mm) leaving the bar end flush with the Nyloc Nut - gaining sufficient clearance to finally bolt the front end into place. Our removable front end is pretty much the same as Geoff's (SpNOam's) except we will have Sports pack Arches to deal with..

I still have my 2 pictures of Geoff's ride taken at Castle Combe taped to the whiteboard - Inspirational :cool:

Here is where we are this evening :D

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120509_204206.jpg

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120509_204115.jpg

The headliner is in place ready to be stretched into place tomorrow night - Thanks to Kenny O'Hare who is good with the task.


I have access to a 2 post ramp on Saturday & Sunday Night (Cheers Dicky)so will make best use of it.

MoT is booked for Tuesday 10:00 a.m. :!:

A few more on my PhotoBucket as usual.

[Purtsi]

Good progress once again! :) btw. Do you need to lift the engine when changing the oil filter? I don't see much gap between the frame and the filter.

Which day you're leaving to Balatonfüred?

[substitute]

Good Morning :)

No Oil filter just goes on without. I would leave a little more space next time. The Green One won't have a modified bulkhead.

We're leaving on Tue.22.May.12 for Balatonfured... Tee Minus 12 Days :-D

[Purtsi]

You got 3 more days than me to get the Mini ready :) I'm just fixing an oil leak behind the dash :D

[substitute]

I have no dash LoL :-D

See you there...

[substitute]

Steady evening yesterday.
Did some essentials first; extending the short speaker wires into the boot and spading up the HRW connection at the C-Post then to business. Concentrated on the interior as Welder Andy had returned the fabricated subframes. They fix to the cross member, a la mini brackets, and bolt to the floor pan at the rear. Had to trim the fixed runner on the drivers side for the handbrake mount and in they went - Very nice, very comfortable :D

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120510_185526.jpg

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120510_185358.jpg

They need retriming but that will have to wait until there is more time...

Kenny from our mini club (and who I share the workshop with) came down to do the headliner with me. It fitted nicely for a pre-owned item off a different mini. First time I have done (helped?) anything other than a mk. I - Another job off the tick-list.

Paul got on with some much needed painting duties, mainly the Rollcage and some smaller visible under-bonnet items.

We all played "Twister" to fit out the rear of the cabin. Rear seats are a bit long in the tooth and the covers don't fit well but they're all I have for the moment.

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120510_210241.jpg

Door Seals fitted and Window seals in place until the glue cures - then ready for Glass.

A productive evening all round. Filled the scrap beer can bin a little higher too.

Hope to get my driveshafts today... more this evening and over the weekend.

Tempus Fugit and Tuesday Looms Large!!!

[substitute]

At least the speedo is ready for the MoT ;)

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/The%20Blue%20Build/tempjpg.jpg

[substitute]

Took some time out from work today as my driveshafts were ready. Rob Walker performance engineering cut the 2 pairs of shafts left last week, turned on a short socket on the larger shaft and a spigot on the smaller one, profiled the joint edges (V) preheated and welded. They are true.

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120511_223437.jpg

Picked up some trim cloth as my brother has produced GRP door cards. I have had a set of GRP cards in my turbo mini (The Red One) since '84 and they have not suffered from wet, damp or anything else over the years... recommended upgrade. cutting keyholes, winder and latch holes tomorrow (later!) a.m.

Glass is in.

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120511_222957.jpg

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120511_223111.jpg

Now looks more like a mini...

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120511_223257.jpg

The Roll Cage...
http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120511_223759.jpg

The Cam Cover...
http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120511_223816.jpg

Going well...

[substitute]

Yesterday morning I took the old door cards and new trim material to my brothers. He has made the GRP flat sheet and will cut to shape and do the clip keyholes and fitting holes ready for us to retrim sometime after the MoT.

Got to the workshop late morning, removed the front and lifted out the engine - 26 minutes!!! - put the shell onto a castor trolley at the front and dropped out the front subframe for a coat of paint by Paul.

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120512_193947.jpg

Kenny and I fitted the doors - a fairly slow and carefull process. The door stays were preventing an easy shut on the nearside. The new inner wing was double skinned at an inconvenient point on the stay swing and was just enough to bind it between the wing metal and the stay slot. some local relief with a steel bar & hammer left it swinging in and out nicely.

Offside door frame had to be eased by hand for the window to rise into the seal sweetly.

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120512_193310.jpg

Rear lights assembled and fitted.

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120512_193337.jpg

Mounts for Shox bolted on and the adjustables hung in place as the hubs have to be removed to pack cv joints, Tighten & Tab the Ball Joints and fit the Vented discs.

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120512_193223.jpg

Off to workshop for the day shortly... with a long but diminishing list of 'to do' items. Looking more like an all-nighter will be needed tomorrow if it is going to be ready for its MoT on Tuesday morning...

[substitute]

Not many pictures from yesterday. Changed the Clutch and Cambelt as insurance.

Interestingly the Borg & Beck Clutch Kit is Labeled Vauxhall. I have read about fitting Nova(?) 'boxes on the Suzuki using an adapter plate.

Andy (Welder) joined me and we put together the Hydraulic Clutch conversion (Thanks to Purtsi for posting the picture for us to interpret).

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120513_102131.jpg

I think a Verto type Slave cylinder will be better for me as my radiator is to be side mounted and the bleed nipple on a verto is up and forwards so would not be covered by the radiator.

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/20120513_102110.jpg

Have had to bump MoT by a day :( as Modified Radiator, 50mm shorter from bottom with a more efficient core design, will not be available until Tuesday.

All-Nighter tonight. 3 of us going for it big style!

[Purtsi]

Have you actually tried the clutch yet? The arm seems quite long and in my Mini we had to cut it about 5cm shorter to get it work properly. Different angle may help though.

[substitute]

Hoping for a fairly light pedal. Prepared to fettle and get right this evening. Cheers :)

[Purtsi]

That's quite the opposite of what I have :D But it works ;)

[substitute]

That's quite the opposite of what I have :D But it works ;)

Whatever works eh? ;)

[substitute]

Cracked on last night and got plenty done. Again, not a bucket load of pictures but her are a couple from Paul...

Modifying the Rod Change. Fixed rod inverted to place rod part nearer Left Side, a few bends and kinks plus skew-welded bolt bush ring. Selector rod straight to gearbox connection. Placed gearbox in neutral and centred the change. Got all 5+R first time. :cool:

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/Photo-0051.jpg

A night work picture... to quote Paul "Keith turning the speedo back"

http://i697.photobucket.com/albums/vv339/RedMin/Suzuki%20Minis%20Build/Assemble/Photo-0045.jpg

Much nearer the MoT and similarly nearer departure for IMM2012!!

[Marcus Nordblom]

swift build:) and nicely done

[substitute]

Thanks Marcus :-)

Headaches would be bigger if it wasn't for all the support & info on the forum. It's great, peeps are fantastic.

Wish there was this much when I built my Turbo in '98...

[Purtsi]

No update for few days? Is the Mini ready for MOT and IMM? :)

ps. Takeoff in 3 hours :)

[substitute]

Not there yet. I think we will be though.
See you at Balatonfured :-D

[substitute]

Joy last night :D when The Blue One started First Pull of the key!! Sounds Great!!!

Dispair :( when we found a blow in the Exhaust manifold inside the 4 into 1 collector... unrepairable in time for MoT.

It's off to Balatonfüred in The Red One tonight for 2 weeks :cool:

Will get The Blue One sorted for Brands Hatch Mini Festival.

So darn close... unforseen show-stopper. C'est la vie.

[Purtsi]

Doh. So close indeed. Good thing that you got a backup-Mini which you can take to Balatonfured instead :)

ps. I'm already at Prague. See you in hungary in few days :)