4EFTE Starlet Clubman nearing completion..LOTS of pics!

[Mini Mad]

Hi guys, been browsing the forums for a while, usually hang out over at Ausmini.com. I've been in the process of building my 4EFTE hybrid mini over the last 6months or so and it's now nearing completion and should be on the road in a few weeks! 8)

Thought i'd post a few pics of the build :)
This is what i started with..
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/frontcut.jpg

http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/engine.jpg

Then it was like this:
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/P1020080.jpg

The Frame:
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Frame/PIC00774s.jpg

Cutting the car up for test fitment:
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Frame%20In/DSC_0004.jpg

Engine in:
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Engine%20In/DSC_0303.jpg

Powdercoated frame:
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Powdercoating/DSC_0169.jpg

Subframe Buildup:
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Frame%20In%20Final/DSC_0243.jpg

Freshly painted engine bay:
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Frame%20In%20Final/DSC_0257.jpg

Brake Setup:
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Brakes/Brakes%20On%20Mini/DSC_0305.jpg

Engine in..
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Polished%20Rocker%20Cover/DSC_0317.jpg

Exhaust:
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Mr%20Enforcers/DSC_0279-1.jpg

Under Drivers Front Guard:
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Mr%20Enforcers/DSC_0280-1.jpg

Water-to-Air barrel radiator:
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Mr%20Enforcers/DSC_0281-1.jpg

Boot Before:
http://img.photobucket.com/albums/v654/jcorin/PJ%20Pickup%20-%20Engineer%20Day/DSC_0522.jpg

Boot After:
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Boot%20Respray/DSC_0561.jpg

http://static.flickr.com/129/319424237_fd80d0a320_b.jpg

Bottom of Fuel Cell:
http://img.photobucket.com/albums/v654/jcorin/PJ%20Pickup%20-%20Engineer%20Day/DSC_0520.jpg

New Rims:
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/A048R/DSC01214s.jpg

Engine bay with a bit more bling:
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Polishing%20Engine%20Bay/IMG_2996.jpg

Me working on the dash:
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Making%20Dash/IMG_3586.jpg

http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Making%20Dash/IMG_3589.jpg

http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Making%20Dash/IMG_3591.jpg

http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Making%20Dash/IMG_3605.jpg

Driveshafts in and wheel alignment done:
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Arches%20-%20Wheel%20Alignment/IMG_4373.jpg

http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Arches%20-%20Wheel%20Alignment/IMG_4395.jpg

http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Arches%20-%20Wheel%20Alignment/IMG_4532.jpg

New flares:
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Arches%20-%20Wheel%20Alignment/DSC_0003-1.jpg

http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Arches%20-%20Wheel%20Alignment/DSC_0008-1.jpg

My new CF Dash:
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Carbon%20Fibre%20Dash/IMG_4644.jpg

http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/Carbon%20Fibre%20Dash/IMG_4651.jpg

And that's about where i'm up to..

Computer needs to be installed, then dyno tuned, engineered and a few little things here and there but shouldn't be too much longer!

Hoping for around 200HP at the wheels.

[duck]

Nice job, mini is looking very very nice.

Makes me chuckle (with envy) your working enviroment, I'm usually in the garage with 3 or 4 layers of clothes on, don't get to work in flip flops very often in the UK :cry:

[Glenno]

lol - Duck if you saw some of the creepy-crawlies getting around in aus, you'd think twice about the flip-flops....... :lol:

BTW - nice work!

Glenno

[Andy_S]

That really is a neat installation.

I vote for a 16vminiclub meeting over in Oz. I'm looking out of my window at another cold wet day!!

That fuel tank with all the inbuilt mountings is a clever solution, did you make it yourself?

[Swiftmini]

Hi minimad, glad to see you joined the 16vmini forum. Your mini is looking great, i like the stack dash 8)

Cheers

[bodgeit]

Nice :D

[minimr2]

fantastic build :shock:

[carl]

brilliant build infact got to be one of the better ones ive seen.

just one thing i cant get me head around, the alternater. it looks like its solidly (sp?) mounted to the subframe but whats gonna happen to the belt tension when your engine rocks back and forth?

carl

[FatKev]

Amazing looking car :shock: :wink:

[Mini Mad]

Nice job, mini is looking very very nice.

Makes me chuckle (with envy) your working enviroment, I'm usually in the garage with 3 or 4 layers of clothes on, don't get to work in flip flops very often in the UK :cry:

Haha, yes the weather is nice, though sometimes a little too hot!

That really is a neat installation.

I vote for a 16vminiclub meeting over in Oz. I'm looking out of my window at another cold wet day!!

That fuel tank with all the inbuilt mountings is a clever solution, did you make it yourself?

Thanks, haha - im worried about my minis rusting over here and we're in dought! :lol:

I bought the fuel tank and had it modified with the mountings, my welds aren't that good 8)

Hi minimad, glad to see you joined the 16vmini forum. Your mini is looking great, i like the stack dash 8)

Cheers

thanks man 8)

brilliant build infact got to be one of the better ones ive seen.

just one thing i cant get me head around, the alternater. it looks like its solidly (sp?) mounted to the subframe but whats gonna happen to the belt tension when your engine rocks back and forth?

carl

Thanks, yes the alternator is mounted to the frame. There shouldn't be enough movement of the engine to cause trouble. Time will tell :)

[gtmini]

Looking really nice mate, I'm almost finished too! Just need to fit the F/G front end and finishing touches. Looks so roomy next to my install, will be interesting to know how the charge cooler performs. Might go that route then I don't need a bonnet scoop... Think you're gonna be screwed with the alt though :( even if it charges it'll squeal like a pig!

Keep on dude!

[B20GT]

That IS probably the best allround conversion I have seen completed, like the BR Wantanabe's 8) beautiful install.

Hats off to this one :D

[Aband]

Nice one i went to a scrappy the other day and saw the same engine lying on the floor. with all its bits.

I would post the photo but i dont want to ruin your build photos as the one i found was rather corroded

[Mini Mad]

Looking really nice mate, I'm almost finished too! Just need to fit the F/G front end and finishing touches. Looks so roomy next to my install, will be interesting to know how the charge cooler performs. Might go that route then I don't need a bonnet scoop... Think you're gonna be screwed with the alt though :( even if it charges it'll squeal like a pig!

Keep on dude!

Thanks mate - goodluck, are there any pics on here of yours? - If alt squeeks to much i have another bracket here where i can just mount it off the block :)

That IS probably the best allround conversion I have seen completed, like the BR Wantanabe's 8) beautiful install.

Hats off to this one :D

Thanks, much appreciated :D

Nice one i went to a scrappy the other day and saw the same engine lying on the floor. with all its bits.

I would post the photo but i dont want to ruin your build photos as the one i found was rather corroded

Hehe go for it..you know you want to :)

---------------------------------------------------

Just a quick little update..

Computer has been installed - Autronic SM4
I scrapped the stock plenum and other exhaust mani i had and got new ones made up which i'm very happy with.

http://img.photobucket.com/albums/v654/jcorin/PJ%20Insight%20Motosports/DSC_0029.jpg

http://img.photobucket.com/albums/v654/jcorin/PJ%20Insight%20Motosports/DSC_0030.jpg

http://img.photobucket.com/albums/v654/jcorin/PJ%20Insight%20Motosports/DSC_0035.jpg

http://i9.photobucket.com/albums/a58/minimetoy/25062007158.jpg

http://i9.photobucket.com/albums/a58/minimetoy/25062007157.jpg


And yesterday it was started for the first time! :D No smoke, no bad noises, nice smooth idle . Very happy!

[Spag]

Nice jobby mister :D

If our 4AGE on Mini suspension is anything to go by, then that should be a most entertaining drive.

Should make some useful power too, ditching the TVIS plates, sticking on a K&N filter and running a free flowing 2" zorst we got 138 horses and 148 torques when the Megasquirt was tested on the rollers. - And that was from a £50 engine of unknown mileage :wink:

[bodgeit]

138 horses and 148 torques

LOL

loverly car by the way. i wish i had the time to build mine to that standard.

Matt

[Aband]

http://i76.photobucket.com/albums/j1/abnaduk/23062007176.jpg

There it is lol!

Question, did u have the turbo manifold cromed? or did you buy it like that?

[Mini Mad]

Hi Aband,

that's a 4EFE (no T for turbo) the 4EFTE is a factory turbo..

It's still good :D

The manifold was custom made to fit the mini and it's ceramic coated for a chrome like finish.

Spag,

that 4AGE sounds nice 8) any vids?

[Spag]

Hi,

There's a couple of the 'first move' and from the rolling road, scattered hiding in the build page...

http://www.spagweb.com/gallery/ed_06_mr_ed

Be amazed how little attention to detail you can get away with when doing the conversion in a month :P

After 11 months 'light' use (he he), passed the MOT with only a tweak to the handbrake cable too
:D

[Aband]

wooops sorry lol :)

[Mini Mad]

Ok quick update..

I drove it for the first time this week :D

Made 150HP atw on 12psi - but having problems with wastegate creep that need to be sorted - hope to push 200atw with some more boost :)

Sorry for the blurry pic
http://img.photobucket.com/albums/v654/jcorin/PJ%20First%20Drive/IMG_2071.jpg

http://img.photobucket.com/albums/v654/jcorin/PJ%20First%20Drive/IMG_2086.jpg

http://img.photobucket.com/albums/v654/jcorin/PJ%20First%20Drive/IMG_2089.jpg

Some vids:
http://www.youtube.com/watch?v=avJkXfp3hOc

http://www.youtube.com/watch?v=bst9EiTCfWw

There is a slight knocking noise coming from the rear engine mount which came loose and is a bit rattly but it's getting fixed as i type :)

Hopefully on the 8th i'll have it at the drags and get some better footage 8)

[Dan]

I really hope you make it to the drags on the 8th.. I will definatly be there to watch :lol:

[Mini Mad]

:lol: Run the GzeVan? :)

Yea, i should make it, just gotta sort out everything, there's alot to do! :( but i have this whole week off so should be ok :)

I bought a bullet cam to do some vids 8)

[Dan]

I was thinkin about running the van... My bro is away for 3 weeks so it is mine til he gets back. I might still do it just not in the group i supose

[Mini Mad]

There is space..a few dropped out if you want to join the group

[Mini Mad]

Well guys i blew it up not long after it got running :oops: :shock:

Did a big-end in i think - it's knocking quite bad :(

Ahh well i have another engine here ready to go in, just a pain to have to pull everything out!!! :(

[BassAddict]

Sorry to hear about the engine - looks like a really tidy conversion 8)

[Mini Mad]

Just an update for those interested, i got the new motor in and sorted out made 182HP at the wheel so far on 19psi but intake temps were in the 50's so have to sort that out - it's running slightly rich (11:1) to stop detonation.

Took it to the drags and managed a 13.457 @ 105mph on it's first night out after 3 runs so pretty happy with that considering the weight (or lack thereof) some of you guys get over there. My car weighs 750Kg wet :shock:

Here's a vid of the run:
http://www.youtube.com/watch?v=_bgeAnnRCMo

And another from the stands - first run ever did a 14.2
http://www.youtube.com/watch?v=SVTqMCZyrQo

[duck]

Thanks for the update on your mini.

Very nice mini and a very nice time at the strip :D

Do you have plans for more boost ?

[matt]

Wow this car is very very nice and i goes as good as it looks. Top work :)

[BassAddict]

Glad you got it fixed up again - and running better than before judging by the figures !! 8)

[Bert]

unning the Stock CT-9 Turbo at 12psi will give you around 150-160hp ATF. Meaning about 130-140hp ATW.


Also running 19psi on the stock CT-9 Turbo is asking for trouble because 15psi is really its max flow. Anything more and you get hot air meaning high intake temps like your seeing.you will get a max of about 205hp ATF using the stock turbo safely.

Thats from a mate of mine who had a 185BHP Starlet Turbo/Glanza V

[Mini Mad]

Who said anything about a CT9?

I have a TD04 on it and it's happily seen 19psi and intake temps are stable at 37degrees making over 200HP ATW. The high intake temps were due to an inefficient water to air cooler that has since been changed.

http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/2008/W2AFINAL080.jpg

This was on 18psi
http://img.photobucket.com/albums/v654/jcorin/Starlet%20Conversion/2008/201.jpg

[Bert]

"You didn't mention that LOL!For 19psi I am slightly dissappointed if it is a TD-04. I would expect a bit more, however, air temp is a big thing. Over here in Scotland I've seen TD04 Starlets run 1.3-1.4Bar and pull around 260-270hp ATF (230-240hp ATW). But we commonly see <10Deg C in the winter.
Are you running Forged internals? 4E + TD-04 + Big Boost = Melt from what I've seen"

[Mini Mad]

It's a smaller TD04 than what you guys would normally see, it's not off a WRX i'm hitting boost around 3000rpm, from most of the TD04 starlets i've seen they are boosting closer to 4k. The motor is stock internals, but i have another motor here ready to rebuild if something does go wrong. I don't drive it much so not too worried.

Regardless it's running conservative timing with an Autronic ECU and M&W CDI Ignition System.

It seems to have taken all the punishment i have thrown at it, i've increased the rev limiter to 7800rpm and it hits that everytime i take it out due to wheelspin.

The weather is a big difference, we're seeing 31deg days at the moment.

I broke a driveshaft at my last drag meet so it's off the road for now..

http://img.photobucket.com/albums/v654/jcorin/Broken%20Driveshaft/WSID%20Break/IMG_2047.jpg

http://img.photobucket.com/albums/v654/jcorin/Broken%20Driveshaft/WSID%20Break/IMG_2053.jpg

http://img.photobucket.com/albums/v654/jcorin/Broken%20Driveshaft/WSID%20Break/IMG_2048.jpg

[carl]

top quality car this, i like it a lot and good result on the rolling road too.

[carl]

oh and do you have any pics of your geabox near you steering rack, ive done a starlet turbo conversion but my engine is further forward than most ive seen on aus mini but i couldnt get it any further back due to diff casing hitting rack thanks

[le1ght]

like this alot ,top work :D

[rabbit]

wow!!!! this is really nice mate!!!

[eightace148]

very tidy car you have made there!
i have a clubman in the same colour I think. dont supose you have the paint code do you? its not an origional colour is it.

top work though.

[dazzamcgoo]

WOW Cool Mini :p

I was thinking a couple of weeks back about a build exactly like this. And a started looking around and found this forum. And here I find someone else in Australia has done the same thing that I want to do. I don’t want to sound like a copy cat but have you got any info on your frame work, what CV joints did you use and have you got any other photos of the front suspension set up?
I was looking at starting my build on a Morris mini shell. Would there be anything that you would have done differently after your build experiences?

[ade1964]

I'm nearing the completion of my 4e-FTE, will upload pics when done