R1 FWD Mini Build

[CH007]

Hello All,

Well after all the help on here and lots of changing my mind I have settled on an R1 conversion.

David (minicooper) on here helped make my mind up with a PM offering his R1 Engine, Cradle, Subframe and Diff for sale.

Stopped by on Friday afternoon after work and ended up buying everything bar Subframe and throwing into boot of car for journey home:D

What an well made piece of kit it all is and if the subframe wasn't designed for 90mm extended front I would have had that also!

I was rushing to get it painted before weather turns but I don't think it's practical and have a feeling i may need to make further mods so will remain in primer at present.

The body is now solid after cutting all rot out and replacing metal. the underneath and wheel arches are in stonechip and finished colour which is ford frozen white. The rear Subframes are rebuilt now with superfin drums and new back plates along with alloy hubs, trunions and handbrake quadrants. Rebuilt radius arms and new braided hoses.

Front will have mini sport 4 pot callipers on 8.4" vented disks.

Whole thing will be running original rubbers and is on height adjustable setup. also gas adjustable spax all round.

Here are a few pics of the bodywork build so far and will get some of engine etc tomorrow and front end and boot is also fitted now.

Oh and roll cage door bar was put higher for protection as have fibreglass doors but will be moving that as can't get into car and sense:p

[Birdman]

Looks like it's gonna be a beauty. The roll cage looks a bit different. Is it tricky getting in and out over the side / door bars? I want a cage with door bars eventually, but I don't recall seeing them go up that high.

[Birdman]

Sorry just read the end of your post - it did have me wondering...

[CH007]

Yeah had a brain fart that day and was on a welding mission lol!

Will be chopped out next few weeks and remounted at correct height:rolleyes:

[RobinJI]

Looks very tidy, I always like the idea of a bike engine in the front. I'll be interested to see how this comes along. Is the conversion kit a bought one or the previous owners home brew?

If you're worried about strength in a side impact it might be worth thinking about crossed door bars, as it will make the central area you need to get in and out reasonably low, while giving the maximum protection across the rest of the door. I'd also consider bracing between the bottom of the legs on the main roll hoop, the standard mini floor pan doesn't really have enough strength to stop them bending in towards each other if hit hard.

[CH007]

Looks very tidy, I always like the idea of a bike engine in the front. I'll be interested to see how this comes along. Is the conversion kit a bought one or the previous owners home brew?

If you're worried about strength in a side impact it might be worth thinking about crossed door bars, as it will make the central area you need to get in and out reasonably low, while giving the maximum protection across the rest of the door. I'd also consider bracing between the bottom of the legs on the main roll hoop, the standard mini floor pan doesn't really have enough strength to stop them bending in towards each other if hit hard.

Hello Robin,

I think the crossed doorbars are the way to go and should lay my hands on some CDS tube to make them shortly. I have got dash bar across front but maybe add in a cross brace side to side. depends how impatient I get:D I will then 3 weeks later end up redoing anyway like with these doorbars lol. curse this attention deficit:mrgreen:

The conversion is homemade although looks as good if not better than some bought kit in it's construction and design. A lot of thought has gone into things like being able to remove clutch housing without removing engine etc.

I may have to modify Diff carrier as it's going to be tight squeeze in roundnose front.

Just going through the pain of fitting fibreglass components at moment and is slow going but needed I think to get the weight right down. The doors are a massive saving and with polycarb windows all except windscreen and rear should be mega light.

[CH007]

OK had a good stab and roughly placing engine in bay and see how tight it is and boy was minicooper right! I have one more thing to try otherwise it's either clubman front or extended as he had already planned:rolleyes:

How much more room at front does clubman have? I have been informed 1.5" and that would almost do it I think.

Anyway here are the pics and i think will agree the scrub line would be a little out if left here:p

[Birdman]

Wow, I never would have guessed the engine would sit so far forward. I don't think you need clubman or extended front ends using the Promotive kit. Might be worth having a look at how they have done it.

[CH007]

Wow, I never would have guessed the engine would sit so far forward. I don't think you need clubman or extended front ends using the Promotive kit. Might be worth having a look at how they have done it.

Well the Pro-motive kit the engine is turned back to front and run through gears to correct rotation so farely complex and with more to go wrong for a simple home build.

The main thing holding the engine forward is the diff and cradle it's mounted in so my next plan is to tilt engine further back and then adjust diff mounting position. I will mock this up the weekend and see how it looks. I am pretty determined to fit into standard size front with minimum subframe mods and keep part count low.

[Birdman]

The R1Manx website may help with some ideas:

http://www.r1manx.com/Components.html

[CH007]

The R1Manx website may help with some ideas:

http://www.r1manx.com/Components.html

Great link that! That's got some ideas flowing and shows it can be done althoiugh they don't state if round nose or clubman front at a quickish glance.

I think though with modifying my current diff mount i could just get it in. In fact it's now a mission to make it fit:mrgreen:

I need to bring the whole thing up anyway for the scrub line otherwise coul dbe nasty when engine comes through bulkhead when passing over speed humps lol!

I have got some box section sorted now so watch this space!

[Birdman]

Great link that! That's got some ideas flowing and shows it can be done althoiugh they don't state if round nose or clubman front at a quickish glance.

I think though with modifying my current diff mount i could just get it in. In fact it's now a mission to make it fit:mrgreen:

I need to bring the whole thing up anyway for the scrub line otherwise coul dbe nasty when engine comes through bulkhead when passing over speed humps lol!

I have got some box section sorted now so watch this space!

I wondered about the diff / sprocket carrier - it did look a bit low. I think you just need to be carefull if you are going to tilt the engine and change the angle it sits at. I'm sure you will get all figured out though..

[Allan McD]

they don't state if round nose or clubman front at a quickish glance.


Heres a picture of the front end
http://farm5.static.flickr.com/4078/4854746814_23e8cda53f.jpg (http://www.flickr.com/photos/r1manx/4854746814/)
Allan

[Minicooper]

Here it is in action first drive
http://www.youtube.com/watch?v=xYqI5-dkMlo

Cheers
David

[CH007]

Thanks for the links. I have the engine just thrown in at present and do have it all too low at present.

I am sure it can be done but won't be easy and will be very tight!

Cant watch vid at moment as on work network but will have a look later.

Can't wait to get stuck into it now. Missus is working friday night and saturday so will be a late one I think :D

Beer, Angle Grinder and Welder! what more could man ask for aside from some hot blonde helping pass spanners :D

[CH007]

Well was seriously impressed with the poke there and would be interested to know what ratios they were running. I will have to drop them a line.

I couldn't see pic at work and see it's now got a clubman front. Does this mean it never fitted correct or just more room? I think it will go into round nose but exhaust headers may poke through grill etc. However I don't mind a big scoop on bonnet so may be able to just get it that way.

So I have box section of various sizes arriving friday along with some EN1A round stock so will see what I can come up with:p

[CH007]

Well been busy at it this weekend.

I have the front suspension rebuilt and fitted on O/S of car and N/S in paint ready for rebuild.

So the front has new wheel bearings, new poly bushes, new ball joints, new 4 pot callipers with vented 8.4" disks finished with spax adjustable shocks.

Picked up the tubular Subframe from Minicooper on friday and have slid that into place now with engine fitted loosely to allow final measurements and adjustments. That was my reason for rebuilding front suspension so early on. this way I know geometry sits where it will when finished and can work from there.

So the front will now need 90mm extension so still deciding if I do this myself or buy one while selling my standard length fibreglass front. the 90mm gives much more room to allow decent clearances should the worst happen.

I figured I am building this to take so track abuse so no point having everything so close that a slight twist or trip over the kerb on track ends in a wrecked engine or diff.

here are a couple of pics

[bear]

did you put a reverse??????

[CH007]

I haven't put reverse on yet but I will, as will be road car.

I will be using electric but something a little different to the norm if my plan works out;)

I am not keen on an inline gearbox as it's more losses and something else to fail.

[RobinJI]

That frame looks really tidy. Must be saving a fair bit of weight over the standard a-series set up. It's a shame you're having to use an extended front, is there no hope of getting it in a standard round nose?

[CH007]

Yes David did a real nice job on sub frame. I think you could get into standard nose but clearances would be very tight between gbox and diff and to me thats asking for trouble. Just worried if a chain gives or something slightly twists when i am abusing it and then it all ends in tears:rolleyes:

hoping to get other side finished by end of weekend along with steering rack in place and perhap start on gear lever setup if i can clear enough crap out the way to get at milling machine:grin:

I may have to push on with bodywork so i can clear shop for all the fab work. looking forward to getting rid of all the mini bits up at castle coombe

[bear]

where you find tha revese

[CH007]

Bear, I haven't got reverse yet and will be making it rather than buying. I don't have all the details figured out yet but have a concept I think will work and should be nice and simple.

[Minicooper]

Lynx AE make a nice compact reverse and the price isn't bad at all, could be fitted to any bike engine by the look of it, with chain drive

http://www.lynxae.co.uk/Products-Bikesports.htm

Cheers
David

[CH007]

Thanks for the link David. That does look pretty good price.



Ok so today managed to get the suspension for N/S rebuilt and mounted along with steering rack and column. So I now have a rolling shell with fully rebuilt running gear. So next step is mount other subframe tie bar then drill holes and make plates for front, rear subframe mounts along with brackets to weld on for flexi brake hoses etc.

I am going to cut off the doorbars the weekend and remount lower to allow access and finish mounting engine. Once I have this sorted then manufacture the gear linkage.

Hoping to get a couple of days on it so should get a good amount done.

Next step is then to make the drive shafts which should be fun but made enough room to get at machine tools now so will make life easier.

[bear]

put some pics off your gear linkage

[CH007]

Yes Sir! :mrgreen:

I will get some pics when I have built it.

I will get some measurements and maybe model it in Inventor first as need to keep up with the young minds on here ;)

[Minicooper]

Hello Colin,
I found some little bits you need to fit the clutch arm, circlip, spring and washer. Send me your address via private message and I will post them to you

Cheers
David

[CH007]

OK got a bit done over weekend.

Got front end built completely and also finished wedling rear engine mounts and thenmade new fronts for new position (slightly tilted back)

Also welded on brake line brackets and made acetal bushes for engine mountings (gave up on rubber bushes after 4 failed attempts lol)

Here are the pics:

I have started design of gear linkage also.

[philster]

looking really good :D

how does the power transfer to the wheels?

[CH007]

looking really good :D

how does the power transfer to the wheels?

Hi Phil,

Going through ATB Quaiffe diff with chain drive. This then has Ford output shafts which will be mated with mini shafts to keep hubs standard. Thats my next major job really.

I will get some pics of diff setup if get a chance

[CH007]

Not really got much more done but been dangling the turbo around the engine bay a bit like divining for water and it likes the back of engine with all that room going to waste:D

I must stay on track though as have also considered slipping another R1 in the back as well. A pile of steel in the garage is just crying out to be formed into a rear spaceframe:lol:

wont be able to get on it for a few weeks now so hopefully the urges will pass:rolleyes:

[CH007]

Ok had a few weeks away from the project while on hols but back now and keen to get things moving. i have made pretty much all the body mods now so will ocncentrate on moving door bars to proper position and welding in bulkhead box etc. i can then focus on getting the car in paint which I need for motivation ;)

This is subject to total change of course:rolleyes:

So going to castle combe this weekend coming and will no doubt come back with more than I go to sell and picking up extended bonnet along with front end hopefully next week.

i can then get doors sussed and ready to prep body.

My drink fueled design sessions on the sunbed have led to a few subtle changes to so will see how they look in cold (sober) light of day :p

[CH007]

Well managed to pick up a pair of Corbeau Forza's at the Castlecombe trackday along with my extended Bonnet:D

I was shocked at how hard some were pushing their cars on the track and damn impressed. One thing thinking you are fast on the road and a whole different story being fast on track!!

I cannot wait to get mine running now after watching them fly round track.

Will hopefully pickup front end this week and can finally finish body prep then get it in paint.

[RobinJI]

I must have seen you earlier. My friend with the blue Metro on gold wheels was eyeing up those seats, and then after wondering if they'd sold yet later on we saw someone sitting in them on the bank just before Quarry.

You might have seen the blue metro on track with me in the passenger seat in the morning, or my other friends matt black mini with white arch's and roof flying around. The afternoon session that his mini went in it had no clutch for the whole 15 minutes! leading to some awkward entry speeds and rather a lot of crunching, and a spin on the last bend of the penultimate lap after we had to let off hard mid bend after he realised we were catching the 2 cars in front at a rather fast rate.

All in all a good day, although the matt black mini did end the day on a tow truck. We got as far as Bridgwater before we think no4's big end's gone. Sounds like a bag of nails being hit with a bigger bag of nails, 8 bar compression, lots of oil in the cylinder and no oil pressure. Woops, ah well, it should be seeing a k-series in it over the winter.

[CH007]

Hello mate,

I picked up those seats and slung them in my boot first thing but was sat in the autojumble right down the end.

I didn't see the blue metro in morning but saw it afternooon and the matt black mini. Looked like great fun:p

I can't wait to get mine running now. Couldn't find the 16v stand either??

come home with more than I left with to sell:rolleyes:

[RobinJI]

Ah right, they may well have been a different set of seats that we were looking at then. The track was indeed good fun, even just as a passenger, kinda wishing I'd taken my daily driver Scirocco out now.

I'm not sure there was a 16v stand as such, not that I saw anyway. I saw Joel up there (XEValver) but that was about it. I'm fairly new to this forum though, so don't know that many people yet.

[CH007]

Ah right, they may well have been a different set of seats that we were looking at then. The track was indeed good fun, even just as a passenger, kinda wishing I'd taken my daily driver Scirocco out now.

I'm not sure there was a 16v stand as such, not that I saw anyway. I saw Joel up there (XEValver) but that was about it. I'm fairly new to this forum though, so don't know that many people yet.

I did see some interesting builds there also. That forge racing mini was so light!

Didnt realise you could take any car out or the lease motor would have been slid round there;)

Well hopefully next one I attend will be with the mini.

tried to get some work done today but couldn't get going and know when it's time to step away. managed to cut out the doors bars and notch them ready but patience wasn't there today to weld them back up.

[CH007]

Well picked up the front end from Birdman yesterday and quickloy thew it on front when i got back. now realise the bonnet needs heating and resseting as the radius on front of bonnet is well out.

Also the extended front has left loads of room for front mounted rad, intercooler and turbo if needed later :mrgreen:

I have hopefully also found a booth to hire so can spray the car and bake properly.

I will hopefully have some updates in a few weeks but work is stopping play at present

[Birdman]

Glad to hear you got back OK with the extended front squeezed into your car. As you say, you should have plenty of room now for front mounted rads / intercooler. Will you need to put a hump in the bonnet you bought still to clear the R1 Cam cover? Also looking at your build diary, I noticed that you have the the powerflex / deflex type of poly subframe tower mounts and tie bar mounts. I don't know what other people think, but I would imagine that eliminating movement in these two areas by having solid top mounts and rose jointed tie-bars will make the car handle much better. There will be a lot of acceleration / decelleration forces tugging the tie bars and subframe backwards and forwards with the R1 Engine and sequential box. Just a thought...

Decent weather forecast for this weekend - I can feel a weldfest coming on..:)

[Minicooper]

The cam cover won't stick through the bonnet but the air filter might

Colin
I still have the clutch lever bits I found, also found a standard clutch cable which you can have if it's any use to you

Cheers
David

[CH007]

Glad to hear you got back OK with the extended front squeezed into your car. As you say, you should have plenty of room now for front mounted rads / intercooler. Will you need to put a hump in the bonnet you bought still to clear the R1 Cam cover? Also looking at your build diary, I noticed that you have the the powerflex / deflex type of poly subframe tower mounts and tie bar mounts. I don't know what other people think, but I would imagine that eliminating movement in these two areas by having solid top mounts and rose jointed tie-bars will make the car handle much better. There will be a lot of acceleration / decelleration forces tugging the tie bars and subframe backwards and forwards with the R1 Engine and sequential box. Just a thought...

Decent weather forecast for this weekend - I can feel a weldfest coming on..:)

I think your right and solid mounts might prove better. I will machine some up when I get a chance from T6 aluminium.

David's right the air filter, or what might be the plenum;) will stick through bonnet unless I modify inlet manifold. I personally like a nice big scoop as mid life crisis is looking so will work one in there:D

Get out there and weld that motor up it's gonna be one nice peice of kit when finished!

The cam cover won't stick through the bonnet but the air filter might

Colin
I still have the clutch lever bits I found, also found a standard clutch cable which you can have if it's any use to you

Cheers
David

Cheers david forgot all about this and also said i would have wiper motor and assembly from you. Dont know if you still have that? If so can pop round in next week or so after work if that suits?

Either that or week after as will be staying up in alton during week for a project installation so could pop down instead of propping up bar one night;)

[Minicooper]

Hello colin,
Yes I still have the wiper motor and stuff, give me a call when it suits

I also have the R1 radiator with fan for a carb engine, also I have a brand new radiator assembly with fan for the injection R1 2002-2004, a couple of clock sets and the necessary wiring looms for anyone else who is building something R1 powered


Cheers
David

[CH007]

Hello colin,
Yes I still have the wiper motor and stuff, give me a call when it suits

I also have the R1 radiator with fan for a carb engine, also I have a brand new radiator assembly with fan for the injection R1 2002-2004, a couple of clock sets and the necessary wiring looms for anyone else who is building something R1 powered


Cheers
David

Cheers David,

I will give you a call when project confirmed.

[CH007]

I have been flat out with work but managed to squeeze in an hour or so. I have now moved door bars to correct position and moved steering column mount from original mini dash to rollcage dash bar. Much more solid now.

I have started lining up front end and trying to line up A panels. Need to go read up on best way to fit these and get it done. I can then strengthen ready for whatever hinge arrangement I go for on doors.

I will try and get some pics up as updates are rubbish without them.

[CH007]

So I got fed up with colder weather holding up spray job etc so went a got a space heater and bottle of gas today. The result was inside of car is now in paint :mrgreen:

I think I had too much pressure on gun as whole inside of garage was a haze :lol:

Basically now engine bay and inside are in paint along with underneath of car I can finish the build and then get it in paint early next year.

I was thinking of hillclimbing and mini sprint series with this car and if I go that way it's just the harness bar or some mounts on rear bulkhead. The rest of build I will make compliant so can have a go if I like.

Here are the pics.

[Allan McD]

Make it in to a racer its easier (no lights etc) and the buzz is amazing.
Allan

[Birdman]

Looking good Colin, whatever the temperature of your garage.

[CH007]

Make it in to a racer its easier (no lights etc) and the buzz is amazing.
Allan

You make a very good argument as I stare at a knackered old wiring loom! How is the resale value of racers? Reason I ask as I enjoy the build most so would no doubt be starting some spaceframed monster once this is complete and run a few laps :mrgreen:

Also if I dont need reverse then I might be tipped over to the dark side;)

Looking good Colin, whatever the temperature of your garage.

:lol: yea it was getting cold (for a southern softy)

I also mis-calculated my hardener mix and made it twice as quick as required! End result as of 10 mins ago it has gone off already so a fingernail wont mark it :mrgreen:

[Allan McD]

Also if I dont need reverse then I might be tipped over to the dark side;)


No reverse needed for racing in our class :D
Allan

[CH007]

No reverse needed for racing in our class :D
Allan

hmmmm I am leaning this way now;)

How far down the country does your class run? I am down in wiltshire so local hillclimbs etc are places such as Gurston etc.

Need to make my mind up now as keep bobbing in between. if it's gonna be a racer I will chop out the roof for a start and slip a fibreglass or carbon roof on and will obviously not bother with original wiring loom as there will be nothing to wire except engine, fuel pump and gauges.

[CH007]

So If I am reading the blue book correct (doubt that very much lol) In libre class for sprint and hillclimb I would need minimum 32mm CDS cage with diagonal across hoop behing head. Aside from the diagonal i think my cage complies.

I have found localish place to me at Gurston that does the hillclimb series along with an HSA site at castle combe so seems there are plenty quite close :D

Seriously considering this now as would let me have much more fun than on road (need my license for job and gone past wanting to drive like looney on road) and woul dbetter suit the seriously stripped out build I had planned anyway :mrgreen:

So I will push on with build in this vain and can always trailer the car to trackdays also.

It's going to be the big push now to have it complete and MSA log booked before next years season starts:D The missus wants a bash at some track fun to, which will be lethal as she is nutty behind wheel :lol:

[Allan McD]

You are correct (I think) about cage.
The missus can do a shared drive with you on the hills and sprints.
Wiscombe park must be fairly close to you as well I have been there at the British championship rounds for the last three years.
Allan

[CH007]

I got grinder withdrawals today so I cut the roof off :mrgreen:

Are sunroofs ok for MSA regs :lol:

I will be slipping a carbon fibre roof on all in the name of a few extra kilos lost and it makes the rest of interior build nice and spacious for head room

Do people just bond them, just rivet or both in the race scene?

[Allan McD]

I bonded and riveted mine.
Allan

[CH007]

I bonded and riveted mine.
Allan

Thanks Allan,

I take it you left rivets out on show? Reason I ask is I am going for exposed weave. I am thinking that nicely spaced rivets could look good at say 100mm apart.

Cheers,

Colin

[Allan McD]

Mine is just a race car so I just drilled a few holes here and there and put rivets in.
Allan

[CH007]

Mine is just a race car so I just drilled a few holes here and there and put rivets in.
Allan

Well mine is race only now also so functional and light is the aim:-D

My only concern is how much protection it will give if I plough through a hedge roof first :lol:

[Birdman]

Well mine is race only now also so functional and light is the aim:-D

My only concern is how much protection it will give if I plough through a hedge roof first :lol:

Hedges are fine. People regularly park in them. I managed to get cosy with an oil drum, which someone had been helpfully filled with concrete on a race circuit. I narrowly managed to avoid connecting with it side on, but it tore the rear upright off the Formula Ford I was driving. It was a bit of a moment.

[joltfreak]

I just bonded my CF roof on my mini.

[CH007]

Hedges are fine. People regularly park in them. I managed to get cosy with an oil drum, which someone had been helpfully filled with concrete on a race circuit. I narrowly managed to avoid connecting with it side on, but it tore the rear upright off the Formula Ford I was driving. It was a bit of a moment.

Lets hope I don't do that on forst time out;)

[CH007]

I just bonded my CF roof on my mini.

Did you bond with tiger seal or some similar seam sealer? just interested what people use

[Birdman]

Lets hope I don't do that on forst time out;)

FWD, you will be fine. Rear wheel drive, Instructions to push as hard as I could and one wheel on wet grass = accident ;)

[joltfreak]

Did you bond with tiger seal or some similar seam sealer? just interested what people use
i used a two part bonding agent called: Fuzor #127EZ. this stuff is made to bond CF race cars together.

cut out the old roof:
http://img.photobucket.com/albums/v284/joltfreak/IMG_0696.jpg

and glued the new one on. i used a bunch of pinching vice grips to hold it down overnight and it was done by morning.
http://img.photobucket.com/albums/v284/joltfreak/IMG_0702.jpg


Sorry about the highjack....

[strudel]

Joltfreak,

Did you get the Fuzor #127EZ in Canada or had to order from the US? I'm in Alberta and may need some of this for a CF hood repair. JS

[CH007]

thanks for the info:)

Did you bond to gutter then? I left 70mm of roof to bond to but maybe thats not needed?

Cheers

Colin

[joltfreak]

Joltfreak,

Did you get the Fuzor #127EZ in Canada or had to order from the US? I'm in Alberta and may need some of this for a CF hood repair. JS

I got it at my local autobody and paint supplier
http://www.yellowpages.ca/bus/Ontario/Hamilton/Dura-Chemicals-Ltd/535155.html

thanks for the info:)

Did you bond to gutter then? I left 70mm of roof to bond to but maybe thats not needed?

Cheers

Colin

i would leave about 2 inches and try to fit it. it's always easier to take metal off than add some on.

[CH007]

Well got out in the garage for a few hours today.

Got the handbrake fitted and working, pedal box painted and in also along with steering column fitted and seat in.

The seat is fitted on standard runners at present to get postions of other kit first then will fit rigid as MSA doesnt allow sliders or flip ups.

Got new master cylinders fitted to brake and clutch but have somehow lost the clevis pins:rolleyes: will try halfords tomorrow but don't hold much help there.

Need to then get cleared up so can get the lathe fired up and make drive shafts.

Also picked up some rose jointed bottom arms and wiper assembly other week so getting ever closer. Work is mega busy at moment so pushing on when I can as I really want to be ready for next season!

Missus is well up for dual drive so somehow need to make seat mounting with 2 positions also.

[The Mighty Mallott]

If you're getting the lathe fired up to make some driveshafts, why not make some clevis pins at the same time?

[CH007]

I should do really but when stuff like clevis pins are so cheap I just buy them:rolleyes:

I have ordered a couple from minispares along with a few more small bits I needed.

Pic up a bigger motor tomorrow so will be a trip to scrappy with all the old engines etc that wont sell to make some room:)

[CH007]

I got one door hung today and almost finished. I was planning on doing the drive shafts this weekend but like some sort of madman I have thrown away the drive shafts it seems:confused: I cant find them anywhere so must have thrown em out!!!!

So on lookout for set of mini drive shafts now:rolleyes:

If all goes to plan I will have both doors fitted this weekend with some sort of catch to hold them closed. I will go to work on hinges once doors fit shaving weight off. I can mill down to half thickness and slip some holes in I think.

I will get pics up tomorrow

[Birdman]

I got one door hung today and almost finished. I was planning on doing the drive shafts this weekend but like some sort of madman I have thrown away the drive shafts it seems:confused: I cant find them anywhere so must have thrown em out!!!!

So on lookout for set of mini drive shafts now:rolleyes:

If all goes to plan I will have both doors fitted this weekend with some sort of catch to hold them closed. I will go to work on hinges once doors fit shaving weight off. I can mill down to half thickness and slip some holes in I think.

I will get pics up tomorrow

I may have some driveshafts if you get stuck, I will have rummage tomorrow, when I go down to the garage for a weld-fest. I think you had a look at the lightweight doors that I have in my garage when you picked up the front end. I believe they have 3 holes drilled in each. With just steel skins, perspex etc I reckon the doors weigh approx 6 kilos each. They came off a grass tracker.

[CH007]

I may have some driveshafts if you get stuck, I will have rummage tomorrow, when I go down to the garage for a weld-fest. I think you had a look at the lightweight doors that I have in my garage when you picked up the front end. I believe they have 3 holes drilled in each. With just steel skins, perspex etc I reckon the doors weigh approx 6 kilos each. They came off a grass tracker.

Xheers mate yes please have a look. Yup i go the idea of drilling off those doors:) I am mounting the fibreglass doors now so they weigh next to nothing anyway.

[Birdman]

Xheers mate yes please have a look. Yup i go the idea of drilling off those doors:) I am mounting the fibreglass doors now so they weigh next to nothing anyway.

I have a pair of Mini Drive shafts from my 1380. I need to retain the outer CV joints as they are handy when mocking up my hubs / moving the car around. I will be looking for £25 for the pair if that's OK. Hopefully I dont snap my vauxhall inner / mini outer hybrid shafts. Just let me know if you want them. ;)

[CH007]

I have a pair of Mini Drive shafts from my 1380. I need to retain the outer CV joints as they are handy when mocking up my hubs / moving the car around. I will be looking for £25 for the pair if that's OK. Hopefully I dont snap my vauxhall inner / mini outer hybrid shafts. Just let me know if you want them. ;)

That sounds spot on;) I have the outer CV joints already so suits me. Would you be willing to post if i arrange courier pickup to suit you?

Cheers,

Colin

[Birdman]

That sounds spot on;) I have the outer CV joints already so suits me. Would you be willing to post if i arrange courier pickup to suit you?

Cheers,

Colin

Yep, never done it before but sounds OK. Let me know how that works - you can PM me. When will you need them?

[CH007]

OK itching all over from fibreglass now and freezing cold but have the first fittin gof new clubman st front end from ABS. I ordered friday night and was here today:D

The bonnet will have a nice big scoop in it for air intake. I am thinking of staying with the wheels I have for now as they fit the arches ok and I am sure my driving will take a while to out handle 5.5" rims anyway.

I will need to make a fairly tight manifold at front to clear but looks so much better than extended front;)

[CH007]

Both doors are now fitted as of last night along with the shutlines on front end to doors sorted also:-D

Just need to sort fixing front of front end which conveniantly sits on top of subframe tube:beer:

Then going to finish driveshafts which I have found now. I hope by end of christmas break to have the drive shafts complete and subframe painted. Just gonna go and order a baffle plate for the engine now as santa gave me some readies;)

[Minicooper]

Looking good Colin, the clubman front is much better than mucking about with a stretched front

Cheers
David

[CH007]

Cheers David it does look much better than the stretched front. A tight fit but it fits all the same:D

Here is a pic of the front end now adjusted to let the exhaust down pipes in.

[CH007]

Well got the plug made up today for my bonnet scoop mould. It's coated in PVA ad awaiting first gel coat and matting. I dont have any gel coat so will just be using resin at this stage as will be painted anyway and is my first attempt at fibreglass.

I made the plug with some decent relief angles (learnt my lesson metal casting) from wood and some body filler to smooth then coat of primer before PVA coating.

Tomorrow will lay up the mould and hopefully have something to show next day. It's pretty hot-rod though as thats the look I love so will be a marmite scoop I think :lol:

[CH007]

Ok have the mould almost finished but think I may use it as the piece as not much point in making a negative mould for a one off piece really. The mould just slid off the plug (read had to to destroy plug :D)

It's a bit vulgar as I love hot rods as you wll see from pics;)

[CH007]

The scoop is now mounted in bonnet from underneath now and first coat of filler on to smooth.

Working on rear quarters at moment also as they are the final major body prep before all the fine stuff.

I am hoping if I get a clear weekend at the car to have it in primer before end of jan.

[philster]

looking good mate, what colour you going for?

[CH007]

looking good mate, what colour you going for?

Cheers mate, it's going to be ford frozen white same as interior and underneath. I have been playing with idea of doing outside a deep blue though with interior and underneath white:D

[CH007]

Oh Pooh!

Fitted sump baffle plate today, new gasket and all that jazz. Went to turn engine over by hand and it's siezed solid:(

Even with big spanner on sprocket it doesn't budge when in gear. Took the plugs out and they have rusty crud all over them so can assume it's condensation build up has caused it. Out of gear it's fine so not gearbox related. I will drop the sump back off tomorrow just to check it's not something out of place there causing this. I would say looking at plugs it's not though.

I have given the bores the wd40 treatment tonight and will see what happens in morning.

This changes things a little. I was planning on naturally aspirated for now as didnt want to strip engine for lowering compression ratio etc. Well seems I may have to now so may as well do all the other work while I am there and bolt a turbo on for good measure. I will carry on and make driveshafts tomorrow as planned as that won't change and rad mounts etc.

damn project is fighting all the way!

[Minicooper]

Sent pm

Cheers
David

[CH007]

I took the flywheel cover today and soon as I put a ratchet on the nut it turned fine! So drama averted for now but when I ruend engine over a lot of water mixed with oil came out. I can only assume big temp changes from spaceheater and the natural swing of temps has caused this.

I have oiled up the bores good and then fogged inside with oil through airline. I have now done filter change and filled engine with oil also as it can only help. Priority is to now get the engine running so I can start it regular etc. Only thing I need to do is a compression test and perhaps endoscope to see if any damage caused.

Funny thing is the bottom end still had a lovely film of oil when stripped.

SO need to order the ali to make my fuel tank, header tank and other bits to get this running (picked up an AC TIG this week):D

[CH007]

I managed to get the drive shafts made today. They are fors inners and mini outers. Turned the shafts down square then bored 12mm into each end. I drove a location pin into place then slid together. I machined a 25 deg angle on ends for weld. I then tig welded with a root and cap weld.

I didn't have any tube to slide over top so will be interesting to see if these hold out:rolleyes:

So next week will get rose jointed bottom arms fitted along with drive shafts. I have ali on order to make fuel tank and breather tank.

Then need to fit the dash so i can wire up and get this thing started :mrgreen:

[philster]

any pics of the shafts?

[CH007]

Sorry Phil, forgot all about it and now they just look like shafts as have been welded then turned down so nothing to see.

Don't know if they will hold up or not but will soon find out:D I have welded some pretty heavy shafts on machinery like this and always held but then the conditions are pretty bad on a driveshaft compared to nice gentle ramp up and down of machines.

[CH007]

So i finally got the drive shafts fitted this weekend along with the rose jointed adjustable bottom arms while there.

I have finished the alloy fuel tank also. This won't comply with MSA regs as hasnt got filling spout but as I wasnt too happy with finish of tank (first one) I wasnt fussed for now as will end up makiing another in future and didnt fancy hassle of spinning one.

Next up is run the fuel lines and start the wiring so i can get this running. Also got rad mounts etc to make also in alloy

[CH007]

got the boot painted tonight ready to fit fuel tank, pump, battery etc.

I have s/s braided fuel line on the way ready to run them all in. I have filter king regulator also and will be ready for fuel by weekend.

Next up will be the wiring so i can get this engine fired up for a much needed boost

[mostdef]

Hi, great build! Looks really good! Sry if I missed it wondering what frame Ur using? Would u happen to have pics of the frame bare as well as complete with motor? Keep up the great work

[CH007]

Took today off work to get some of the mini done as the slow progress is getting on my nerves now:mad:

So got the fuel tank presure tested and found a few pinholes from not ramoing down curent slow enough at end of weld. they are now corrected and the tank is air tight.

Fitted fuel tank, pump, regulator and braided fuel line today. Also made an ali plate to cover heater holes and to route fuel pipe through.

I then finished by fitting ali plate over hole in bulkhead ready for regulator to bolt onto for cooling and also went a bit mad with tehw riing loom cutting everything I don't need and probably some I do :lol:

This thing will be ready fairly soon I think and may even have made arrangements for the 16v sprint at barkston in July:D

Here are the pics:

No more progress this weekend as have stag do to attend :beer:

[CH007]

Hi, great build! Looks really good! Sry if I missed it wondering what frame Ur using? Would u happen to have pics of the frame bare as well as complete with motor? Keep up the great work

sorry dont have any pics of just frame. Minicooper who posts on here made it and I bought it.

I looked at pro-motive etc but they look quite fragile due to extra drives to bust etc, just my opinion

[Birdman]

Good progress Colin. That's a bit feaky, today I looked at a blank for the bulkhead and the heater hose bulkhead plate and found I have some stainless sheet. Marked it up and will be making them tomorrow.

Enjoy the Stag do. Looks like you've started allready with the 3 cans of "wife beater" in the pics. Glad to see you have your priorities sorted -1) take day off to work on Mini, 2) at weekend get smashed on Stag Do. ;)

[CH007]

Good progress Colin. That's a bit feaky, today I looked at a blank for the bulkhead and the heater hose bulkhead plate and found I have some stainless sheet. Marked it up and will be making them tomorrow.

Enjoy the Stag do. Looks like you've started allready with the 3 cans of "wife beater" in the pics. Glad to see you have your priorities sorted -1) take day off to work on Mini, 2) at weekend get smashed on Stag Do. ;)

LMAO my whole mini is built on "wife beater" fueled sessions in the garage:D Thats the reason I got so zealous with the wiring loom. In the cold light of day next weeknd will probably be swearing as I can't get it to run :lol:

[Birdman]

OMG sad to hear this news mate. :(

[CH007]

Cheers mate but my own doing and own decision so feel worse for her than myself.

So you want the car ;)

[Birdman]

Cheers mate but my own doing and own decision so feel worse for her than myself.

So you want the car ;)

Just let me win the Euro Millions tomorrow evening first...

[CH007]

Well the mini didn't sell and glad it didn't really as got the ecu now firing correctly but wouldn't start, tested compression again and it was real low this time!!!

Well it turned out the valves had crud over them from being stood and some moisture. Head is now stripped and exhaust valves lapped, just need to lap intakes, reset valve clearances and new headgasket to complete. Luckily these older R1 engines can have valves lapped as the newer ones have titanium coating so cant be done without drastically shortening life.

Decided to get this thing running and painted as its not going to sell until finished.

Fuel system all worked fine and dash now fits just needs final fettling.

Oh and back with wife and all going well so over the moon :D

[Birdman]

Well the mini didn't sell and glad it didn't really as got the ecu now firing correctly but wouldn't start, tested compression again and it was real low this time!!!

Well it turned out the valves had crud over them from being stood and some moisture. Head is now stripped and exhaust valves lapped, just need to lap intakes, reset valve clearances and new headgasket to complete. Luckily these older R1 engines can have valves lapped as the newer ones have titanium coating so cant be done without drastically shortening life.

Decided to get this thing running and painted as its not going to sell until finished.

Fuel system all worked fine and dash now fits just needs final fettling.

Oh and back with wife and all going well so over the moon :D

Celebrate good times - come on. Glad to hear all that news mate.

[cooper_mark]

happy days....glad things have sorted themselfs out
get on and get it finished....;)

[philster]

get on and get it finished....;)

Then keep it :cool:

[CH007]

Cheers Lads,

Keeping it is a matter of funds at present but trying my best to keep it for a while.

Working most weekends at moment but hope to have it running in a month or so.

[CH007]

Car is now all one colour:D

Went for black as nice contrast to White inside. Just need to flat and polish rest of panels left.

I will post some pics up weekend. Just need head gasket to reassemble engine as timing either slipped or wasn't right so bent valves! New head ready just need gasket.

Have full set of polycarbonate windows on way also.

[Birdman]

Car is now all one colour:D

Went for black as nice contrast to White inside. Just need to flat and polish rest of panels left.

I will post some pics up weekend. Just need head gasket to reassemble engine as timing either slipped or wasn't right so bent valves! New head ready just need gasket.

Have full set of polycarbonate windows on way also.

Good Stuff.

[CH007]

Good Stuff.

Cheers dude, had a quick look at your build log today it seems are moving along well.

Here are a couple pics of it in paint. The white arches and black paint make it look like it's in a dinner jacket:rolleyes: Will be added white chequer to roof and may paint rims white???

ANyway next up is fit the dash properly and get a steering wheel on there along with wiper switch etc

[Birdman]

Cheers dude, had a quick look at your build log today it seems are moving along well.

Here are a couple pics of it in paint. The white arches and black paint make it look like it's in a dinner jacket:rolleyes: Will be added white chequer to roof and may paint rims white???

ANyway next up is fit the dash properly and get a steering wheel on there along with wiper switch etc

Yes, I'm sure you know what it's like mate, family, relationships, work commitments. It's usually the Mini project that suffers, otherwise you run the risk of getting grief. "moving along" is correct and not far off. I haven't had my paperwork back from DVLA yet, so that is on my mind. I'm also working on parts of the conversion to build in some reliability, or at least make it possible to do repairs without removing the entire engine etc. I think making it to Mini shows is becoming less of a priority to me now, it's more about having the car useable for day to day activity. I want to be able to drive to Europe and beyond with it.

Your Black paint is looking good.

[CH007]

Not sure whats happened to hybird forum but it's a bit like my build, all to pooh!

So I have managed to get rear of vehicle done with alloy light blanks, polycarb windows etc finished.

Got the new R1 head back on today and also did valve clearances. Car ready to start but turning over real slow. turned out starter is knackered (probably from cranking it so much before without letting it cool. So new startyer motor on way and hopefull yhave this running by end of week.

Notice cheap tacky chequred roof decal, I like it as it hides some of my paint job;)

I have cut dash holes also and picked up all the brake fittings I need to pipe up.

I am aiming for completion so I can take it out at the miniworld action day, castle combe.

[philster]

I am aiming for completion so I can take it out at the miniworld action day, castle combe.

good luck :cool:

[CH007]

IT'S ALIVE I TELL YOU ALIVE

Turned it over just to check new starter motor with no throttle or intention of it running and it started:D One mistake I have made is i killed battery and it wouldn't stop as running from alternator so need to sort out kill circuit to ECU.

Overall i am very happy and will get coolant system and clutch/brakes done so i can test drive it!

Here is my first 3D model and it shows my gear shift lever which will use a push pull cable.

[Birdman]

IT'S ALIVE I TELL YOU ALIVE

Turned it over just to check new starter motor with no throttle or intention of it running and it started:D One mistake I have made is i killed battery and it wouldn't stop as running from alternator so need to sort out kill circuit to ECU.

Overall i am very happy and will get coolant system and clutch/brakes done so i can test drive it!

Here is my first 3D model and it shows my gear shift lever which will use a push pull cable.

Excellent news mate. It really is quite a shock when you just flick the switch and it immediately springs into life. Chuffed for you, having reached this milestone - now get some proper 13" wheels - LOL:D

[CH007]

Excellent news mate. It really is quite a shock when you just flick the switch and it immediately springs into life. Chuffed for you, having reached this milestone - now get some proper 13" wheels - LOL:D

LOL if things go to plan with work, and they rarely do! New wheels and keeping car may be on horizon:D

I was jumping around like fool when it finally ran and itching to get finished now

[Birdman]

LOL if things go to plan with work, and they rarely do! New wheels and keeping car may be on horizon:D

I was jumping around like fool when it finally ran and itching to get finished now

Yeah it spurs you on. I think I may go to MITP just to get an enthusiasm fix.

[CH007]

when and where is that mate? Hope you not been out looting

[Birdman]

when and where is that mate? Hope you not been out looting

This weekend I believe at Santa Pod. I've just decided to sell up and move out of the UK, so as you can imagine, I've stupidly loaded myself with untold other work and have to finish the Mini as well.:rolleyes: I will most probably drive the Mini abroad though.

[CH007]

Good luck with sorting move mate have considered myself!

Cant make this weekend so will have to shelve that one myself.

[Minicooper]

Colin,
Glad everything is ok in the end, I will need to double check but I have a curved ZX9r rad and electric fan which can be donated to the project FOC. I know it's been squeezed at the bottom but the guy assured me it was watertight, I will check it carefully in the morning and let you know

Cheers
David

[Birdman]

Good luck with sorting move mate have considered myself!

Cant make this weekend so will have to shelve that one myself.

Cheers mate. It could be one hell of a drive all the way to Istanbul. I'll just be based from there and travelling all over Europe more. Would be nice to take a detour in Germany to the Nurburgring. I must be mad, but there again my neighbour trusted me enough to rebuild an old Ford Sierra and we drove that all the way to Greece, so anything is possible.:cool:

[CH007]

Colin,
Glad everything is ok in the end, I will need to double check but I have a curved ZX9r rad and electric fan which can be donated to the project FOC. I know it's been squeezed at the bottom but the guy assured me it was watertight, I will check it carefully in the morning and let you know

Cheers
David

That would be great and very much appreciated David:D Yeah finally got there! needless to say i will no longer be using a space heater in my garage, i think the rapid swings in temp caused the condensation that caused engine probs and my machine tools to rust:pissedoff:

How is life at present? Hope all is good and that mini coming along

[CH007]

Cheers mate. It could be one hell of a drive all the way to Istanbul. I'll just be based from there and travelling all over Europe more. Would be nice to take a detour in Germany to the Nurburgring. I must be mad, but there again my neighbour trusted me enough to rebuild an old Ford Sierra and we drove that all the way to Greece, so anything is possible.:cool:

Do it while you can, life is short so make it count:D

[Birdman]

Do it while you can, life is short so make it count:D

Yep, it will be quite cool to do that Road Trip. I'll be sure to take photos and post them up of the journey on here. Beer is calling me now.....;)

[Minicooper]

Hello Colin,
I had a look at the rad and fan, tested the fan it works fine, I have had the garden hose blasting into the rad and there are no obvious leaks although it is a little differcult trying to plug the outlets on the rad whilst holding the hose but it appears ok. So it yours if you want it. Like I said it's been squeezed at the bottom and the fan support is a little wobbly but the unit is usable

Cheers
David

[CH007]

Hello Colin,
I had a look at the rad and fan, tested the fan it works fine, I have had the garden hose blasting into the rad and there are no obvious leaks although it is a little differcult trying to plug the outlets on the rad whilst holding the hose but it appears ok. So it yours if you want it. Like I said it's been squeezed at the bottom and the fan support is a little wobbly but the unit is usable

Cheers
David

Cheers David that would be great:D I am not working in your area at present shall i send you some money to post?

[Minicooper]

I will sort out what it will cost, Monday is better for me as I'm mostly not here on the weekend

Cheers
David

[CH007]

So managed to get manifold put togther today but need more parts to complete exhaust. Also fitted the clutch pull cylinder along with piped up front brakes so a good couple of days in all:-D

[CH007]

Ok so have had a major unturn as bagged me a V8 lump and fancy the drag strip! So the whole front end is for sale a bolt in and go assembly. It's in for sale section