Bertie B16a1

[taylor]

few pictures before i move on this is Bertie it was affectionately named by the previouse owner simply B reg: Bertie, bertie b reg. a 998 auto that had covered less than 20.000miles before being layed up in a garage. and then some 10 years later it came into my possesion.

it looks a bit rough round the edges and is but essentially it can be sorted alot is just surface rust in the pics, since starting this diary i have come accross several areas of rot in the usual areas but with the ease of access to new panels it has made it alot more conveinient to replace a panel rather than plate it.

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/100_0569.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/100_0535.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/100_0565.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/100_0573.jpg

[The Mighty Mallott]

Hi Taylor, don't leave a space after clicking the img button, or before the last one for that matter!!
Good luck with the build!

[taylor]

ok sorted it was down to the BBcode being clicked on

[rwdvvcmini]

its linking

first the tag

can be put in by hand or from the above tag list

then a full path to the photograph ie http://www.rwdvvcmini.co.uk/project/week16/mini_w16_b1.jpg

then close it with a

if the path is correct you get

http://www.rwdvvcmini.co.uk/project/week16/mini_w16_b1.jpg


full line would be

http://ww w.rwdvvcmini.co.uk/project/week16/mini_w16_b1.jpg

or

link_to_photo

hope this helps

what i think youve done wrong mate is not kept the text clear.

keep a clean line between each photograph line and the next

ie

explanation rubbish /// clear enough
/// clear line
[img]http://www.z.com/mini.jpg/img] /// pic tag stuff
/// clear line
blah blah /// and so on

[The Mighty Mallott]

cutandpastelinkhere

[taylor]

been wasting time on the net and came accross this site you have to register but its been useful. iv found a section on removing the immobiliser from a p73 which may come in useful
http://forum.pgmfi.org/index.php?sid=8e98c3a6476da7ec2f344ec806090072

[Dowz]

Good looking project. What have you painted your gearbox with? it looks excellent.

Keep the pics coming now you've mastered linking them.

[taylor]

thanks, it was screwfix's brand of high temp aluminium paint. It did take a while to prep the surface tho engine block will be done in the same way and a nice red rocker cover when it gets round to it.

paint link:
http://www.screwfix.com/prods/58951/Paint/Metal-Paints/No-Nonsense-Aluminium-Paint-1Ltr

[Dowz]

Thanks for that i'll get a tin next time im passing. Worth the effort making the engine look new and spangly, its all about the engine.

[crewesmissilesrob]

will the b16a1 engine take the a2 box just like that ?

i seem to remember theres a difference in splines on the clutch and or some other reason you couldnt just throw an a2 box on an a1 ?

i know b series parts are all interchangable just dont remember it being done ? surely more people would have done it if it was that easy for guys using a1 ? or is it a case of changing the flywheel and clutch assembly

can anyone clear this up ?
i had a1 and just converted the slave from cable to hydro for around £60 all in .
and in the pic looks like you have a box on the engine what are you doing with that ? cos im after a cable a1 box

rob

[crewesmissilesrob]

and in the pic looks like you have a box on the engine what are you doing with that ? cos im after a cable a1 box

godamm shouldnt answer posts whilst drunk !

and then check my pm box !

DOH!!!!!!!!!!!!

[taylor]

i believe the clutch and flywheel will be different but il find out when i get to it. iv already pm'd you about the gearbox

nice picture to have a look at i read the transmission will fit the b16a1, a2s, b18s, and b20, one thing to watch would be the vss is different but they are also interchangeable so you could fit a digital into the mechanical and vice versa
http://www.invoauto.co.uk/images/Products/Clutch%20Flywheel/clutch-3d-detail.jpg

[crewesmissilesrob]

yer i know i checked my pm's straight after posting and realised it was you

DOH !

[taylor]

doors when i took them off didnt appear to be too bad but all became apparent when i took a closer look and the bottom half of the skin fell away!
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/100_0567.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/100_0566.jpg

already had the door reskinned from months ago but got fed up and left it, so today iv had it out cleaned it up and primed it.
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0031.jpg
drivers door new skin
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0043.jpg

[taylor]

had this delivered a few days ago its a b16a2 thermostat housing to be fitted incase i do go the route of running 0bd1
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0044.jpg
next job is drivers fitch and remove re-fit new sill

[taylor]

update: pictures of the offside fitch repair and new 4.5" sill is now in, ground and anti rust primed.

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0050.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0051.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0052.jpg

started to line up the fitch repair for the drivers side and found a slight discrepancy in the non genuine panel. at the top hinge hole on the drivers repair panel it is approx 10-15 m in from the curvature but the drivers is arround 25mm so iv pushed the drivers fitch pannel inwards to get the correct spacing so il have to redrill the hinge holes.

holes lined up note: curvature to body
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0055.jpg

repositioned panel note curvature to body
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0054.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0053.jpg
panel marked, cut body cut ready for rusty fitch to be removed and new panel to be fitted.
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0056.jpg

i dont want to bore everyone with body work but its part of my build, i have ordered allspeed drive shafts and when i have finished the drivers fitch and sill i will be moving on to the subframe build, il keep it updated cheers guys

[taylor]

more bits being striped checked and painted.

wiper motor i had some spare time at work this week so i took the wiper motor in stripped it and used the blasting booth to get rid of the surface rust and prep it for paint, i was going to change the brushes as routine but when i examined them they were hardly worn so it wasnt needed.

before
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0057.jpg
after blasting and reassembled
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0058.jpg
after paint
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0060.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0059.jpg

[taylor]

been out today done abit on the mini, finishing off from last week id already marked the fitch out and cut the existing one out and cleaned up the surfaces and anti rust treated them. new fitch is now in, scuttle panel in and closing panel in and ground.

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0064.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0065.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0067.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0068.jpg

this is the reason i was replacing the drivers sill ater abit more proding arround tho it exposed alot more than i would have liked, i now have to strip back the heal board and investigate further and i will definatly have to fabfricate a new rear subframe mount braket as the one in has perished.
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0066.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0070.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0069.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0071.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0084.jpg

[innohs2]

very good job :)

[taylor]

been finishing off sections of the body work drivers sill is done, scuttle repairs are done with closing panels jusrt need grinding down n anti rust primered untill body prep, that rust hole you see to the left of the clsing panel will be drilled out and a grommet fitted and used to feed the washer bottle wires

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0094.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0095.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0096.jpg
I have the left and right quater repairs, refit the boot floor to wheel arch braket and refit the fuel tank braket and clean the roof skin up and body work is ok and on to prep.

the allspeed shafts i mentioned previous have arived and so have the new left and right honda b16a shaft assemblys, just need the outer mini cvs and i will assemble them.

I have made a start on the subframe, using the mini frame as a start i offered the hydro box up to its approx location and trimmed the steel work from the rear of the frame.

I have used 1" angle iron accross the turrets
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0091.jpg

the side mounts are made up of several different agles which end up to a 45 at the bottom which lead onto the front of the frame this should give a little more surface area on the joints to weld and hopefully a nice finish will result

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0089.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0090.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0088.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0086.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0087-1.jpg

[taylor]

managed to get a few hours out in the garage so i finished off yesterdays task.

the brace bars are tacked in aswell as the front cross memeber the picture will follow have to charge my phone first. one thing i found frustrating was being careful of how much the original subframe flexes during modification.

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0092.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0093.jpg

[taylor]

small update today i had the day off so spent a few hours on the mini. finally ground the scuttle panel and drivers sill and anti rust primed them. removed the front seats and carpets, removed the original sound proofing from the front so i can clean the floor up and lay some dynamat or equivilent. managed to lay abit of U-POL seam sealer as well so not a bad day.

done some more on the sub frame too, front cross bar taked in to hold it square removed the inners from the original subframe and fab'd up the start of the lower subframe.

this is what it looked like when i started this afternoon
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0098.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0099.jpg

after id finished todays task
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0100.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0101.jpg

[taylor]

update: been out in teh garage today with my friend chris who helped me lift the engine and offer the subframe after a fare few attempts we managed to get it in. (thanks to darmon for borrowing me the engine crane)

problem areas was the gearbox side of the subframe i had to remove alot of the mini frame to get it in, we nose dived the gearbox in the frame first and then lowered the cam side down to clear the belt pully then we pulled the engine back over to the cam side of the subframe.

eventually tho we did get it in: roughtly first signs are good it did
all go in although i didnt have the mounts on but there not needed at this stage. I can now build the lower structure of the subframe arround the sump and gearbox.

few pictures of todays task

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/minisubframe001.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/minisubframe002.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/minisubframe005.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/minisubframe006.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/minisubframe004.jpg

as you can see from the cam side tiebar veiw the sump is obstructing the path so i will be adopting the modification method to the sump

[taylor]

update: been plodding arround in the garage this week tweaking the engine trying to get it to sit where i wanted and since i dont have the outer cvs yet i have to build a degree of flexability into the frame ie the engine has to be able to slide left and right in situ.

I removed the pre fab'd structure i fitted last week and started work on the lower cradle by offering the rear part of the mini frame up to the engine and building arround the gearbox and sump and then up again.

its not perfect yet i have a slight twist in the ds crade and when the frame is bolted up to the car the front rises so il need to break my spots and re align it down a few degrees

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0120.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0122.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0123.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0124.jpg

[bennivory]

frame looks good mate, have you done your tie bar mounts yet? what size box have you used.

[taylor]

i have looked at that i have a few options open to me either use the mini set up with poly flex bushes and fab a mounting pont or turn down some tie bars and cut a thread on them and use rose joints.
Im more than likely going to go with the later and use rose jointed lower arms that way when its tracked up it can be done perfectly.

Il keep the diary posted with pictures it wont be for a few weeks yet.

frame is over kill at 40mmsq 3mm wall (i got it free)

[taylor]

not too much done this weekend i mainly cleaned up the garage, changed the flex on the grinder and purchased a clubman grill.

leading on from what i was saying last week about when i offered the subframe up to the mini and bolted it up the front was high so i ground all my spots off and reset it so the brace bars and lower frame were level in situ.

Im going to get it to work sometime this month and weld it up on our 3phs stick welder by then il hopefully have enough spare cash to get my outer cvs from allspeed and i can start getting it together and fabricate the mounts and the tie bars

a few minor problems but nothing too bad these have to be expected when undertaking such a task.

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0152.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0153.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0155.jpg

[Birdo]

Thats a nice beefy looking frame, shouldn't have any problems with strenth for that one. :)

[taylor]

managed to get the frame into work during the later stages of this week and welded it up, i intentionally didnt weld the front cross member up as it will be fabricated so that it can be removed to assist fitting of the exhaust manifold.

its not completet yet i still need to get the outer cvs and fit it all together and then i can get the location of the engine mounts. il also thread the tie bars and weld on the brackets for them aswell

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0190.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0188.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0189.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0191.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0192.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0193.jpg

[taylor]

got my tie bars back from my dad this afternoon, he works for brush traction who do the service and overhauls on the eurotrains and he kindly took my bars into the machinist at work n they cut me a m16 left hand thread to accomidate the rose joints.

thanks to them guys for squeezing them in its a fantastic job.
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0210.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0215.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0213.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0214.jpg

[taylor]

its been a few weeks so im just keeping my build diary active, its not all been time off over the last few weeks iv managed to get my self a crv rear diff, prop shaft and did a long round trip from macclesfield to dorset and back on sunday to collect a near complete front subframe which was a bargain at £20 cash so i just need to get some more steel box and a few plates of flat and il be cracking on again.

edit: have had a long think about this 4wd mini it will happen but not with bertie i was looking at the work iv put in on it and dont have the heart to cut it out again so its staying as is.

iv ordered a new rear subframe and some new trunnion pins going to waxoil the rear today and press the bushes into the mounts

cheers

[taylor]

I finally got round to cutting the bulkhead for the airbox, i cut my sheet made three tacks and then the weldor decided its tierd.
further investigation revealed its a contact relay thats burnt out so il order a new one on tuesday

any way pics of the what little i did do.
for reference to anyone who is using a sip migmate gas/gassless weldor: the wire feed pcb relay is a 250vac to 12vdc 16A switching capacity. RS part number 351-639
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0256.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0255.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0254.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0257.jpg

[taylor]

repaired the board today and some more parts have arrived. The steering rack is off and is in the workshop ready to be stripped inspected and painted with new boots, 'rack ends, u brackets and friction strips.

This is the relay that i removed today
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0265.jpg
Iv pumped the sills of waxoil and also painted the front inner arches and arround the lower bulkhead in undecided weather to rust seal up to the front mounting points or re spray it with the airbox.

[taylor]

today i feel like iv moved forward with the mini iv got the steering rack in my workshop its been cleaned up inspected and all is well, iv got the parts through today so im going to fit them in the morning il get a before and after shot.

tonight has been successful as iv refitted the board to the weldor and after abit of a dodgy start ie the weldor feels totally different i made progress.
I did do a very scrappy weld that im not best pleased with but the penatration was there but i got used to it and adapted.

box in bulkhead welded in.
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0266.jpg
Im still undecided weather to paint up to the subframe mounts in rust seal
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0267.jpg

[taylor]

pics of the steering rack.
pics of condition i took it off, after a clean up and greased and finally reassembled
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0264.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0263.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0265-1.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0269.jpg

[taylor]

well its been a while since my last update and i am ashamed to say iv not done too much within that time. I have managed to free a few hours up over the weekend and come up with a solution to my tie bar problem (thats been haunting me for a while now). Rear subframe has come and is painted in anti rust paint.
The clubman front has also come thanks to body stylist at abs motorsprt for that.

jobs to do:
I need to get the doors back on the car so i can get the A-panels lined up and welded on then, order the outer CVs from allspeed and assemble the drive shafts. when thats done i can get the engine in and fabricate the mounts.

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0334.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0333.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0273.jpg

[taylor]

I made the 45* blocks yesterday with a 16mm hole through the centerers, today iv been out and put it together as my sketch above. i drilled the holes for the bolt to go through and ended up filing them oval so i could get the angle correct through the box section. just tacked them on and put an inch temporary weld on the blocks so i can assemble the tie bars and hubs ready for the next stage of engine position
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0335.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0336.jpg

[billyboy83]

Looks good fella, but wont that mount for the tie bar be very close to the sump and gear box ?

[taylor]

during the subframe build i took alot of pics for reference and looking through these its defiantly going to be tight but it should be OK, IL know more in a few weeks when i buy the outer CVs and get the drive train and engine in to fab the brackets.

more build pics:
http://s401.photobucket.com/albums/pp100/carl2157/mini%20vtec/?start=100

[taylor]

Thanks to Shane for quick sale of the CV's, assembled the shafts today just need a metal tie around them. assembly were built from new Honda drive shafts that i had imported from the US allspeed shafts and CV's. They went together very easily a credit to allspeed for there manufacturing.

A-Panels have been fitted to Bertie and tie bars are out again getting the thread cut on clevis side and the rear wheel arches, underside and front bulkhead has been rust proof painted
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10246.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10248.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10247.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10249.jpg

[taylor]

I wasn't happy with the access of the subframe i built so iv built a second version this still uses the standard points and will have poly bushes fitted once complete. I didn't want to go solid mounts with it because I'm using rose jointed lower arms and i want a little 'give' in there.
The frame uses the 40mm box for top arms, lower arms around the rear,10 mm box and struts across the towers and 30mm box for the front cross member (not on the pics)
Iv only put an inch weld on each part just to hold it and already the frame seams a whole lot more stable with less tendency to flex. http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0364.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0365.jpg
Iv made some templates for engine mounts so Il be making them this week

[taylor]

I took the frame to work today and welded it up iv started the mounts and tie bar plates so should have them done tomorrow.
Engine is in the frame on bricks and chocks of wood to get the levels correct, drive shafts in with hubs so when i do finish the mounts i can get them on now and leave them.
The second picture is lining the master cylinder up behind the bulkhead (copied from HELEN vaux build) iv got my manual pedal box in the garage so il have a look at it soon.
The red marking on the frame is red oxide paint i had spare in the workshop.
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0367.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0366.jpg

[taylor]

Been busy at work and finished the frame, tie-bar mounts are in position, engine and gearbox brackets have been made and welded up and iv given it a paint needs at least one more coat.
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10307.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10305.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10306.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10309.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10304.jpg

[taylor]

On the 12th September 2009 my good Friend jack passed away as a result of a freak motorcycle accident. Jack was a good Friends and we shared many interests including motorcycles, engineering, cars and his favorite Honda's.
Jack was the reason i began building he didn't know about it i wanted to surprise him when it was done but now i cannot. Instead as a token of appreciation i would like to dedicate this build to him.

King Of The GoldWing Rest In Peace.

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/5570_116988526878_517016878_2760576.jpg

[*franky*]

sorry to hear bout that mate. sounds like he would of liked to see the finished car.

[MiniMike]

A great tribute.. rest in peace Jack

[Mintegra]

Sorry to hear about Jack mate... Im sure he would have loved the suprise you had in store for him...

Are you intending welding some cap ends ot the open sections of your frame??... also is it possible for you to add some extra metal where it joins the original frame, It just looks a little weak at present!...

All in all though mate its coming along great!!

Chris

[taylor]

thanks for the support guys.

mini: Yes iv put plastic caps on the ends and yes I will be adding plates into the frame. Been carrying on with rubbing down bloody hell what a rubbish job! Iv had a few strange looks from the neighbours because the roof has gone and it’s got no nose or doors or boot!

[Mintegra]

Cool!!.... Tell me about it... what an arduous job, you have only just started :-) got to do it another few times yet I expect!!...

C

[taylor]

The gussets are now on and painted. I'm using black polyflex bushes as you can see from the bottom picture. hi-lo kit and new knuckles are on there way, top arms have been painted and i have ordered new bearing kits for them.
I'm still rubbing down, Becky and me have decided for safety were going to fit bucket seats so I'm going to remove the rear pockets and the lip of the seat. It will make it easier for me to fit the cage and rub down.

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0376.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0375.jpg

[taylor]

Iv not had time to work on Bertie recently with work commitments and various other projects but I have sourced some parts ready:

A new set of HI-LO
new knuckles all round
new top arm bush kits
copper brake pipe and bender

up rated lower tie bars have been fitted to the subframe with rose jointed bottom arms. will be ordering new front bearings next week and ball joints so this pretty much means everything upfront will be new.
Iv been keeping an eye on the post by Thrash911 about the Sherpa brake conversion so providing this does work out successfully then I will be going down the same route.

[taylor]

This is a rough drawing of my subframe use as a guide only: all drawing are not to scale. measurements in MM

passenger side: cam belt
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0010.jpg

[taylor]

This is a rough drawing of my subframe use as a guide only: all drawing are not to scale. measurements in MM

front brace: sits in front of the exhaust note: standard cast exhaust
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0012.jpg

[taylor]

only a small update, top arms are now in, hi-los fitted on standard donuts. engine went in without too much drama as well as shafts and lower tie bars.

next job is to remove the sump and cut a small piece out for clearance of the tie bar and fit the baffle kit at the same time.

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10450.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10453.jpg

[taylor]

I had a few hours out side today and finally got some time for the mini not too much has happened apart from iv started fitting the boot lid and bins are out in prep for the cage. I'm either going to buy a multi point cage or get a 6 point and weld some extra bracing in where i want it time or money will decide that.
A few change to the original plan are now in progress. The plan was to use grp roof skin, thats now been changed to carbon fiber.
my steel floor repair is now going to be cut back out and a carbon floor fitted : that should be arriving soon.
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10692.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10688.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10693.jpg

[taylor]

Been out for a play today. cut the corner of the sump out and welded it back up again and fitted the baffle. needs to be flushed out and repainted again.
I welded some plates in for the dzus fasteners to hold the boot lid but iv decided they were not right for this application so i have gone with the traditional bonnet pins they should be arriving this week.
should be a fairly productive Christmas for me as long as all the parts arrive i can crack on and finally get the primer on.
So finally after the sump is painted and refitted this should be the last time the engine has to be removed from the frame again, i can do the cam belt whilst in situ.
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0381.jpg

[taylor]

It was going well: I had the sump cleaned off and painted thats ready to be refitted. new oil filter fitted to the engine. front subframe was fitted to the car ready for the front to be fitted (roughly). Battery box was marked up and drilled into the floor, and boot floor removed for gain way for its Cf replacement. Then it started to snow.

yesterday was the first time i could see it all coming together after so long. still along way to go but I'm happy with the progress. Iv been eying up some fiberglass doors but simply cant afford them so may just stick with the steel and tweak em.
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10755.jpg

[taylor]

todays progress went fairly well. been making up the brackets for the engine cam site is OK gearbox side needs raising slightly. then alternator bracket needs to be made. should be an easy fabrication as theres lots of room down the cam side of the engine.
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0384.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0383.jpg

[renessy]

Cheers for your build mate but how are you going to open your doors the way they look now?

René

[taylor]

Iv got some steel plate that I may weld into the lock side that will encorporate a latch and handle.

[taylor]

well finally the snow melted and time to wander into the garage and disturb the peace again.

I'm waiting for the roll cage to arrive, its been around three weeks since i placed the order so shouldn't be too far away.

Its one of those situations where you cant go forward without that part or piece being there I.E. i cant mount the epas until the cage comes and i get it in.

I unintentionally built in a design floor into the lower arm bracket of I didn't allow enough pitch for a larger bolt so iv had to make some bushes to accommodate the M10 bolt to the 1/2" ID of the rose joint.

I actually made made two sets one set top hat and wedge profile. we run a wedge profile on the extruder's at work and I'm not a fan so I'm going with the later. like everything they will wear so iv made a drawing and will get our tool maker to make me some hardened and turn these brake disc's down.

seat members are in (overkill on the steel 50 by 25), Becky had a transit van turn into her passenger side as he tried to go round the outside lane all the way round the roundabout and almost wrote her Bini off so thats why the design.
They'll be some pics at a later date of the members.
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/Photo-0386.jpg

[taylor]

Not a lot to say in this update just that finally the roll cage has arrived so the last parts of the fabrication have been taking place by the end of this week it should be done.
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10081.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10076.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10082.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10080-1.jpg

[taylor]

circumstances have changed recently so the mini has now been relocated back into Macclesfield, Iv been working on it this morning iv put one of the drive shafts back into the car but the CV boot clip broke on the other shaft so i am tying to locate some more. **If any one has any spare let me know**
A for actual build progress the boot lid has been fitted for the fasteners and appropriate holes drilled, the second door bar has been fitted made it today and i have now fitted all the bracing for the power steering just needs a final measure and drilling.
I was thinking of adding some extra bracing maybe some smaller OD tube I am not sure its needed though its a six point cage with gussets that bolt into the door pillars so technically 8 point we will see.
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10111.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10112.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10113.jpg

[taylor]

Roof bracing is now in and welded up, floor mounts have been welded in, door bars are on, steering is now in welded and bolted.

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10115.jpg

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10117.jpg

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10119.jpg

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10114.jpg

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10120.jpg

next step is to clean the whole lot up a task I'm not looking forward to!

[vidievider]

great build great info and pics cant wait to start my own

[taylor]

Iv been off work recently to "relax" so its given me the opportunity to spend time at the farm getting on with this painting.
The pics are not great but there has been alot of time spent firstly cleaning the roll cage up and painted in order for the roof to be bonded on and that had to be done before i could clean the floor up.
That has now been done and painted in a thick hamerite to help protect it.
I aim to get the boot floor, arches and bulkhead cleaned up and primed by next week.

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10156.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10157.jpg

[taylor]

Things have moved a little faster than i was expecting and heres the update:

Front bulkhead has been painted for rust prevention and I did try some of the final paint I actually did the whole bulkhead yesterday but I found the Left side was going "orange peel" so I'm going to have to rub it back and do it again.

The carbon roof has been bonded on and has excess resin removed last night.

Boot floor has been cleaned up and again painted so thats ready to be sprayed. In general I'm quite happy with the progress obviously I would like it to be faster but theres only me doing the body prep.

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10158.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10160.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10161.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10159.jpg

[taylor]

It was an eventful weekend. The paint i applied to the mini bulkhead didn't work out as well as i wanted so i rubbed it back and started again, then I rubbed the sides, roof boot just about everywhere in one day, my only company being a crate or beer.
Saturday my dad came up to give me a hand and ended up spraying the primer on, He did a really good job considering its the first time hes had a go! Any way first layer of primers on so i can get to filler and rub down again.
Slowly I am starting to enjoy this process but its defiantly not for me.

I also made a lower engine mount and purchased a trade pack of CV clips so the other drive shaft can finally go in. just need to fabricate a rear engine mount some time this week.
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10177.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10175.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10163.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10178.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10179.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10181.jpg

[taylor]

Its been a long time since Iv been doing anything on the mini. unfortunately I suffered some stress related health problems during mid 2010 and 2011. So everything was put on hold whilst I gathered myself up. Any way I'm Fairly good again, my concentration is coming back and my brain is working again.

This is how it was: Just a week off Willy spraying it.
The bumper I made myself, I had a look for a chrome on but the price tag was crazy!

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10565.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10566.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10583.jpg

Heres what I have been up to recently:

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10590.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10606.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10639.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC10640.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC11038.jpg
http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/SDC11041.jpg

[kcchan]

ohhhhhh, I'm liking it!

[taylor]

I've been out in the workshop for most of the day. Spent an hour or two on the lathe making insitu adjustable rose joints for the bottom suspension arms. steering rack is in. I also managed to bend one of the ball joints flat. Reasons stated in a previous post on the forum.

http://i401.photobucket.com/albums/pp100/carl2157/SDC11074.jpg

http://i401.photobucket.com/albums/pp100/carl2157/SDC11071.jpg

[taylor]

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/DSC_0008.jpg

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/DSC_0003.jpg

http://i401.photobucket.com/albums/pp100/carl2157/mini%20vtec/DSC_0006.jpg