Mini-Ota 4A-GE FWD [In Bits again £999Re-Run 3/7/09]

[Dazzler]

Hey guys time i started a build thread on here...

Before i start and give you the brief for this i would like to make you aware that this is more of a "scrap heap challenge" using off cuts and re-cycling as much of the cars as possible, so where as most people would buy nice correct metal, we are using either what we have, found in a scrappys or what was already fitted to the cars.

So here we go:

Aims:

To build and compete in the PPC £999 Challenge
Complete a sub 10minute lap of the ring SRR09


Budget:

£999 or under

Car:
Classic Mini FREE
Toyota Mk1 Mr2 FREE

Plan:

To build a classic mini complete with toyota running gear

Target Bhp:

150

Heres the build:

Date:
22/12/2008
Money Spent
£0
Time:
20.00-1am
Work Done

1. Steam cleaned MR2
2. Brought in MR2 and removed engine and running gear

20-15 Toyota nearly Clean

21-20 Engine nearly out (honest)

00.59 (its out at last!)
http://www.staffsminis.co.uk/images/..._P231208_00.59[01].jpg

Hands on
Dazzler
Fartinmartin
Dangermouse (evening teaboy)

Date:
29-30/12/2008
Money Spent
£-30
Scrapman gave me £30 for the MR2
Time:
2 days in and around other jobs (5 hours total)
Work Done

1. Stripped all other bits of MR2
2. Tidied Back room out
3. Moved MR2 out
4. Moved mini in
5. Got MR2 Collected

working on the MR2 (29/12/08 12.30)



http://www.staffsminis.co.uk/images/..._P291208_12.30[01].jpg

Workshop tidy and engine in place ready to play(29/12/0



Bye Bye MR2

http://www.staffsminis.co.uk/images/..._P301208_12.37[02].jpg

Hands on
Dazzler
Red5

jnr update
Just sat the body over the engine to see what room there is...

Subframe building tomorrow!


http://www.staffsminis.co.uk/images/..._P301208_18.00[01].jpg

Date:
03/01/09
Work Done
Cut down subframe to check for clearances and get a general feel for position
Time

5 hours
12.41

17.02


It looks from the pics like nothing has been done, however lots of progress today, got the engine in the position where it is going to sit with suspension towers in place (std mini front cones etc), gearbox clears, pulleys clear, drive shafts will clear and fit so... Monday we will make the first mounts to hold the engine to the towers which are fitted.

For a round nose this is going need custom inlet manifold and exhaust as first thought, but for clubman the std exhaust will fit with enough room for a front mounted rad.

Date
10-11/01/09
Money Spent
£0
Project total
£-30
Time:
13hours over 2 days
Work Done

Made front subframe mk1, fitted all suspension componants, fitted to car, placed on wheels to check for clearances.

Sounds like not a lot, but honest, its loads of work!

http://www.staffsminis.co.uk/images/..._P100109_16.41[01].jpg



Just checking, it looked good


Its in and on its wheels!
http://www.staffsminis.co.uk/images/..._P110109_21.30[01].jpg

Hands on

Dazzler
FATLAD

Date: 23/02/2009
Time Spent: 19.30-22.30
Money Spent: £0
Total Money: - £30
Hands on: Dazzler & FartinMartin
Work Done:

So tonight we have really kicked back in, we started by making a mock up Exhuast Manifold out of toilet paper tubes, we then did something similar to the inlet to give us an idea of space etc.

We have modified the Oil Filer housing and removed the oil cooler plate

We then moved onto the Gear linkage, which i am please to tell you that from draft we have completed, all we have left to make is two cable holders which we will prob do on the car!

I only have a couple of pics which are not worth showing, however when the linkages are complete with cables i will get them up

Date: 01/03/2009
Time Spent: 11.00-18.00 today 1hour Yesterday
Money Spent: £3.90
Total Money: - £26.10
Hands on: Dazzler & FATLAD
Work Done:

Lots of bits so... heres the story starts yesterday

Well yesterday was soooooo funny we went down to the local scrappers for some tube to make the inlet from, found what we wanted went to the guy in the yellow coat

Daz "how much for this"
Man "whats it worth to you"
Daz "dunno maybe a tenner"
Man " dont be silly give me a fiver"
Daz " ok i will get me wallet, can i throw it in the van"
Man " quick get it in the van, quickly"
Daz (puts hand in pocket pulls out £3.90) "I have 4quid in change"
Man "quick give us the money and grapes off, the owner is coming"

LOL, looks like we have paid some random £3.90 for some gear from the scrappy we laughed all the way home!

Next up we have been using that steel and random pipes to make the inlet manifold
heres to pics, its not finished yet
http://www.staffsminis.co.uk/images/..._P010309_13.12[01].jpg
http://www.staffsminis.co.uk/images/..._P010309_15.20[02].jpg




jnr update
Had ten mins on it tonight, i think you get the idea how its shaping up, i will have it finished for the weekend!


Ok then two Updates

Sat & Sunday Subframe time spent: 12hours over two days
Cost: £0
Workers: Dazzler & Bleet

Removed subframe, added tie bars and strengthening also finished off the mounting point on the Gearbox side, the only thing left to do on the frame now is rear engine mount & Alternator bracket.

Also added front bar


http://www.staffsminis.co.uk/images/..._P150309_14.34[01].jpg



Update 2

Tonight Inlet work: Time spent 2hours
Workers: Dazzler
Cost £0
Total Cost £-26.10

Tonight i have made more progress on the inlet tomorrow i will be porting it smooth and then placing the ends on

[pantera2075]

That frame is somewhat dissimilar to mine Daz:-

[Dazzler]

Originally Posted by pantera2075

That frame is somewhat dissimilar to mine Daz:-

Wow, to hold the same engine they are totally different!

[matt]

So what are you going to spend the £999 on
Good progress keep the pictures coming.

[spNOam]

Impresive....subframe looks workable with the side/top bracing welded, keep up the good work, look forward to seeing your next update

[terryg]

daz have already spent the money on tools lol


terry

[Dazzler]

Ok, this is a partial update the rest will come in a propper write up sometime sunday i would think with pictures and stuff

We have fitted the engine and frame back into the car and have found we need to mod the sump as it fouls the tie bar, we though the gearbox was going to catch however a quick tester with me jumping up and down on it, i am a full 18stone gave us full travel and has had the floor touching the gorund without and further probs

Will take some pics of the sump later we are just about to start if for the night shift!

[Dazzler]

Update time...

So there has been lots and lots done, too much to list in my usual way, heres the shorts

i was -£26.10
I have spent:
£230 (front end, roof, boot) NOW CLUBMAN 2 PART FRONT
£15 metal for boot floor and tubbing

So thats £245.00, less the £26.10 (gonna call that 25 for ease)

So i am at £220 spent

Other updates, i have been given by Ives a fuel tank from a tigra complete with fuel pump, the scooby bax box is out and out of the exhaust shops "free" second hand stuff i have had a "Astra GTE back box"

So heres the pics

This is where i was upto, frame in the car back on its wheels roof cut out ready for fibre roof skin



heres the Inlet test





Then the front was cut off to make life a whole load easier while making stuff

heres the home for the alternator



The sump fouled the Tie bar, so thats been cut and modded



The inlet was taken closer to finishing





Ok, so this weekend lots done and focused on getting the body ready-er for MOT lol

free stuff is how it started



Then a big hole was cut



Then the flat floor went in



Then the exhaust was fitted for maximum ground clearance



So, the arches are tubbed the back end is low and 90% done

the only big choice i have now is do i fit the bumpers or de-seam it on the back?

[matt]

Your flying with this conversion keep the good work up.
I would have to say de seam the back. Smooth bum

[Owen]

Loving this! What do you reckon this whole project is gonna come in at? (obvs under £999).


I'm with Matt, gotta go for the smooth rear end

[Dazzler]

cheers, well i am a little pushed for time to do a propper de-seam on the rear but will see

A lot will depend on how much i spend on "bling" i think its going to be around 500-600 by the time i have a digi dash, bucket and harness

will see!

Tonights update

I have been busy getting the shell ready for MOT so i have rolled the shell on its side to make it easyer, i have done repair work to the whole side of the car, finished the tubbing and the underside of the boot floor

Here it is



and another view before i start on, showing exhaust position



after several hours its now welded then seam sealed ready to do the other side tomorrow before clean and paint



Martin has been busy sorting out the loom on the engine which is complete in the frame on a pallet

oh i fogot a tenner needs to go on the budget for the rear valance

[Dazzler]

Right then tonights update

Rolled it on its other side and sorted that out heres the before and after





Then a quick blanker was made for the fuel neck hole




The boot has now been completely finished and is seam sealed ready to go



So tomorrow will be working on the front of the shell i am still hoping to have this painted for the weekend then the build up can begin.

[Dazzler]

I forgot to add this, for those that are wondering why i made a custom inlet

heres the std one in position

[Dazzler]

Update time:

Last night, still welding the shell, its a total shed! no pics as i was too busy, i would say i am 75% done welding the shell, this should be finished tomorrow....

I have taken tonight off welding its starting to bother me, so me and mart have turn our attention to the wiring



Had about 2 hours at it, we have go the ecu system working and starter etc so we are happy that we can make it run using the toyota fuse box, so we will be bringing the mini loom to the toyota fuse box and it will go from there

Jobs left to do

Drive Shafts (materials here monday)
Finish Shell welding
Build up for MOT
Fit roll cage
Paint shell
Wire up
Sort out cooling system

Exactly 1 month to go until the event!

[pantera2075]

Daz,

Mr2 wiring diags here:

http://opc.mr2oc.com/

Go about half way down the page under "electrical" - not the bgb stuff.