Rocketcoffin's 91' D powered Mini

[rocketcoffin]

finally decided to post up a build thread. Bear with me as I catch it up to the current status of the car...

so, I have a 91 mini that I bought at a Japanese auction and imported to the US. I drove it around for about a year before I decided the under powered (25 hp to the ground on the dyno at the shop I worked for) carbed motor had to go. I have quite a bit of experience with Honda powered cars, and love the reliability and inexpensiveness of the setups. I decided to go with the d-motor swap as I did not want to extend the nose with the flip up kit (plus I got a low mile JDM D motor for free) I started by pulling everything apart and piling up Honda parts.

After the dismantle -

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/100_3775.jpg

After pulling the OE motor and selling it, I tore into rust repair. Here's a few shots of the rust I found -

Driver's rear window sill -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/100_3753.jpg
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/100_3754.jpg

Drivers windshield corner -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/100_3755.jpg

Passenger door -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/100_3764.jpg

And the worst of it - the base of the driver's door -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/100_3761.jpg

Other than that, the fenders were pulled off because one was crushed in an accident, and when I pulled it off there was rust in the front grill section and the other fender, so I said screw it and pulled the whole front off.

Dismantled front -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/100_3758.jpg

[rocketcoffin]

Rust Repair -

Patch panels on DS Rear Window -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/100_3931.jpg

DS front windshield corner repaired and seam sealed -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/100_3927.jpg

Patch Panel in ds floor pan by far the worst rust spot i had -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/100_3918.jpg

New Pedal Box from a fellow mini modder- great work done on it -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/100_3913.jpg

Installed -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/100_3933.jpg

Had some parts for the motor powder coated -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/realcoatings026.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/100_3923.jpg

[rocketcoffin]

I thought the way mini-tec suggests to handle the intake problem with the couplers was kind of poopy, and I love fabbing, so I made my own setup.

I cut a stock d motor manifold (retaining the injector bosses and fuel rail mounts), and after porting it out, welded small 2" diameter aluminum extensions to it. I then added 90 degree rubber couplers.
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/100_3935.jpg

Then, using some 2" u-bends, and a piece of 3" pipe, I fabbed up the runners and main chamber. I also added a bar with 3 ports for vacuum references.
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/100_3965.jpg

Here's a shot of the inside -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/100_3942.jpg

I then ordered a ported 76mm throttle body (for B-motors) and made a mounting plate for it.
You can also see the intake air temp sensor mounting spot in this pic on the foremost runner.
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/100_3964.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/100_3957-1.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/100_3950.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/100_3963.jpg

By using this setup, I was able to move everything up and over itself to cut about 3" off the overall length of the intake manifold. I wanted to make the whole setup removable in several pieces in case I ever needed to pull it apart and get at the injectors under the main chamber, or at the back of the motor when its in the car. Also, I wanted to retain every sensor and Honda part I could to help with the street-ability. On some setups I have seen, people leave out sensors, or get rid of things like the Idle air control motor, etc. I want to daily drive this thing, so I am trying to keep everything that helps with smooth idle, and drive-abilty.


Then the mini tec kit showed up -

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSC02188.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSC02197.jpg

Along with other assorted new parts -

Lightened fidanza flywheel -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSC02132.jpg

XTD Clutch -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSC02125.jpg

Besides gathering parts, the task of rebuilding the transmission has been the most time consuming so far -

New LSD unit (no one tire fires) -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSC02128.jpg

Decided to rebuild the tranny - (so much damn fun)
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSC02238.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSC02234.jpg

New syncros, bearings and seals - the tranny should be nice and fresh.
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSC02354.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSC02352.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSC02374.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSC02381.jpg

I also modded the gas tank. Since I am keeping all the stock gauges except the speedo, I have to keep the original fuel level sender, so I just made an in tank pump setup using a walboro 255.

Hole for new pump cradle in top of tank -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSC02399.jpg

Using the Honda cradle, and extending it to put the pump at the bottom of the mini tank resulted in this -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSC02404.jpg

Finishing up the tank -

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCF2123.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCF2124.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCF2129.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCF2133.jpg

After paint -

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCF2136.jpg

After a bunch of running around, misc. parts hassles, and dealing with a bitch of a snap ring, the tranny got assembled - it shifts nicely and is ready to go -

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCF2115.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCF2114.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCF2117.jpg

[rocketcoffin]

Modding the floor for the RHD steering rack. The rack bolts to the engine cradle and needed a little more clearance as per the mini-tec RHD steering adapter kit:

Cut out -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSC02420.jpg

New panel tacked in place -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSC02421.jpg

Pedal Clearance box - you can see the steering shaft poking out -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSC02425.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0429.jpg

Seam Sealed -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0430.jpg

Undercoated -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0431.jpg

Putting the alternator onto the motor with the Mini Tec parts -

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0436.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0437.jpg

Also got the new rear suspension setup from mini mania the other day - new shocks and springs to replace the rubber cones -

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0435.jpg

Then I Scrapped off all the wax-like undercoating material that was chipping and falling off the underside of the car so I could throw on a layer of proper coating -

Who says you need a lift to get under a car?

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0443.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0442.jpg

[rocketcoffin]

All stripped -

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0444.jpg

And after the fresh double layer of 3M undercoat -

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0448.jpg

A little motor assembly -

Got the flywheel and clutch onto the motor (after an emergency run to a good friend's house for some bolts) -

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0449.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0450.jpg

The tranny onto the motor -

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0452.jpg

Then the motor into the cradle and onto the car -

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0455.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0456.jpg

So Im a huge powder-coating nut. I like it not only for the looks but also for the durability and protection. That being said, I sent some parts to the powder coater -

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCF2162.jpg

and after -

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0469-1.jpg

Starting to come together -

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0472-1.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0473.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0476.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0474.jpg

Axle assembly - Honda axles and mini axles:

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0481.jpg

Turn into a set of hybrid axles -

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0484.jpg

[rocketcoffin]

More coated parts - brakes / hubs / suspension:
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0485.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0694.jpg

After re-building the wheel bearings and ball joints:
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0490.jpg

After painting the calipers (and accidentally throwing the left side caliper away, damnit) I threw the front brake / hub setup on the car:
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0690.jpg

Also got the clutch / brake reservoir mounting bracket I made back:
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0489-1.jpg

And mounted -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0692.jpg

As sometimes happens, things that were made have to be re-worked. I forgot the clearance for the adjustable FPR, and the bracketry for the throttle cable. So I had to do some welding and re-powder-coating:
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0696.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0695.jpg

Also recently got the rear sub-frame pulled off and powder-coated, along with the trunion bushing mounts. I ordered some poly busing inserts, and used those to re-assemble everything:
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0660.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0663.jpg

Also scrapped off the weird JDM undercoating on the rear underside of the car and undercoated everything -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0658.jpg

[rocketcoffin]

.....And finally getting caught back up to present day -

I recently did the shift linkage:
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0634.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0655.jpg

While at my local salvage yard I cut the floor out around the shift-hole of a civic, and took the shift rod under-boot. I fabbed up a plate and tacked the under-boot section from the civic onto it, then riveted it it to the mini floor and seam sealed it:
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0698.jpg

With boot:
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0699.jpg

As seems to be happening with every part of this project, when I do one thing, I find 3 more things that need to be completed... when I pulled the rear bumper, there was rust on the rear bumper mounting trim section. So I cut the trim out between the bumper mounting tabs to eliminate the rust spots. I may have to reinforce this later if it's too flimsy to support the rear bumper...

I also fixed a small dent in the rear under-bumper panel and sprayed some primer / paint over everything for protection until the whole car goes in for paint:
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0703.jpg

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0702.jpg

and that is where I am currently. Plans for the next few days include mounting the rear sub-frame back up, getting the rear suspension arms powder-coated, rebuilt and back on, and starting to tackle the horrible wiring mess inside the car....

[Glenno]

Liking that Intake manifold - very nice work! Some nice detail in your build too!
Just 2 questions; is the rubber petrol safe? I know petrol here in NZ can chew threw stuff pretty quick! And what sort of strength is the rubber?-Will they distort at all under vacuum?

Good work

Glenn

[Mintegra]

Another top draw American based build!... you guys over the pond have too much money !!...

Awesome build tho matey!!..

Chris

[pippy]

Really nice! perfectionist at work! love the power coating looks A1!
like mintegra said Awesome build!

[rocketcoffin]

Thanks guys, I appreciate the comments. I am actually unemployed right now, so I am definitely not rolling in cash to throw at cars... I trade work with the powder-coater, who is a personal friend, so I guess I am lucky in that aspect of the build.

Liking that Intake manifold - very nice work! Some nice detail in your build too!
Just 2 questions; is the rubber petrol safe? I know petrol here in NZ can chew threw stuff pretty quick! And what sort of strength is the rubber?-Will they distort at all under vacuum?

Good work

Glenn

The rubber elbows are nitrile (gas safe) and about a 1/4 in thick. They are actually from a trucking supply store and are used on Semi-trucks, so they are really heavy duty pieces. I have used them before in 3 and 4 in sizes on large displacement ( v8 ) turbo applications and they have worked out great.

The whole idea behind the manifold was to avoid notching the firewall, but I miscalculated and ended up having to anyway - it was that or change the design. I don't have any Idea how well it will work out flow-wise, it could take power away, who knows. Every person that sees the car asks what company made the manifold, though, so that's a compliment I will always take. ;)

[Glenno]

The rubber elbows are nitrile (gas safe) and about a 1/4 in thick. They are actually from a trucking supply store and are used on Semi-trucks, so they are really heavy duty pieces. I have used them before in 3 and 4 in sizes on large displacement ( v8 ) turbo applications and they have worked out great.

Nice one - its looking a very smart solution indeed!


..............Every person that sees the car asks what company made the manifold, though, so that's a compliment I will always take. ;)

:cool::cool::cool:

Cheers

Glenn

[jaymeh]

tidy wee build

[B16a2eg]

awesome build! very clean

[jayare]

Nice looking build - I like the finish on the manifold and some of the other parts - what type of powder coat is that? Does it have a trade or generic name?

JR

[rocketcoffin]

The powder coating used on the manifold and misc. parts is wrinkle black. Im not sure of the brand name, but most coaters will know what you are talking about if you ask for crinkle or wrinkle colors.

Haven't posted an update in a while, even though I have been working on the car almost every day. Most of my time with the car has been involved with the rear brake project, which I haven't quite finished yet, but will post about when I finally get it done.

Got the heater hoses run into the car. You can also see the brake bias valve mounted in this pic -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/Picture005.jpg

Mounted the Idle Air Control Valve off to the side of the motor since there was no place on the manifold itself for it. I considered not running it, but I want this car to be as street-able as possible -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/Picture004.jpg

Mounted the ECU -
http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/Picture003.jpg

I am finally going to buckle down and do the wiring with a friend in the next few days....

Will update asap.

[wilp99]

good luck with the wiring.. i just finished mine and it took me about 2 weeks. but im using honda relays (turn, headlight, etc.) with mini switches (took a lot of thinking.. which is hard for me to do sometimes :))

[Mini fab]

Saw your Fuel line in stainless, May I know what size the stainless braided hose is? Tnx man! Nice build by the way!

[Hario']

When you cut the rear bumper seam off did you weld the three sandwitched sheets? (rear valance, boot floor rear panel) because the part you cut off was were the three panels are spot welded together..

[rocketcoffin]

Saw your Fuel line in stainless, May I know what size the stainless braided hose is? Tnx man! Nice build by the way!

- I am using -4 stainless braided fuel line for the feed and return. Its not huge, (although it is larger than OEM Honda fuel line) but Im not going for anything crazier than a slightly modded setup, so it should be just fine.

When you cut the rear bumper seam off did you weld the three sandwitched sheets? (rear valance, boot floor rear panel) because the part you cut off was were the three panels are spot welded together..

- I spot welded the panels where it was cut, then seam sealed over it - hopefully the ass end stays together.... :D

Anyway, made a little progress today- threw the modded tank back in and wired the tail-lights / pump / level sender. There was also a wire in the EZ harness for a trunk light, so I still need to wire that and the licence plate lights.

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0849.jpg

Also put the new tail-light to body seals in, as well as the seal around the fill spout-

http://i99.photobucket.com/albums/l299/rocketcoffin/MINI/DSCN0850.jpg

more to come.....

[MINIMAD30]

how is this build coming along? id like to know how your manifold doing =)