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Birdman's B204 MINI (Mid Engine RWD)

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  • #76
    Have been playing around with intercooler orientation. I will try something this week, that I think might work and reduce the pipework by around 30%. Will have to see if it works in practice ..
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    • #77
      image_10572.jpg Drivers side driveshaft assembly with intermediate shaft, bracket, bearing and both CVs, arrived from Spanish breakers.. In great condition all cleaned and good to go.. Wish I had ordered the other side from them now. So have installed it onto back of engine. Driveshaft angle looks pretty good. Length wise I think with some slight engine adjustment to the drivers side, it may work out, but need to order alloy bearing carriers now to be sure. It's in the ballpark I think. This will be good, if I do not have to have a driveshaft made on that side and was the plan.

      The alternator can now relocate to the SAAB 900 position off of the intermediate shaft bracket, but I have had to order a cheap alternator that has the extended nose for the pulley. Trying to get back into the driveshaft side of issues before fixing brackets for trailing arms. 20201005_124203.jpg20201005_133631.jpg20201005_133639.jpg
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      • #78
        Also got a proper SAAB 900 expansion tank for £4 20201005_133716.jpg
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        • #79
          Have decided to mount the intercooler pretty much on top of inlet manifold. This means the cooler air will immediately enter the manifold and cut out hoses and tubing on that side of the engine. I will have to modify the outlet pipe slightly and the forge dump valve and inlet air temp sensor will have to be in the end of the intercooler tank just before the throttle body. The cooler should be sitting just ahead of rear parcel shelf area. Add a couple of pull fans I think. The pipe run on the other side should go down the back of the engine and under the frame , keeping cool with air flow over it, before coming up to the turbo. I think this will avoid as much heat as possible.

          Got some Autograss shock clamps, and had a play with these. They fit 1.25" tube and I have 35mm so I will get some tube of correct diameter which will brace the main hoop to the diagonal bars. This is just as they do on autograss cars at about 60 degrees. That should allow me to use the JRZ coilovers more upright at around 60 degrees. 20201114_152749.jpg 20201114_152729.jpg 20201114_152327.jpg 20201115_142536.jpg
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          • #80
            Following that I bought a cheap alternator with the extended nose pulley. Even with this, I am going to have to weld both pullies together as an easy fix to get the belt run aligned. Must be just the collection of parts that I have had to source.

            Got mucked about a lot on driveshaft for Passenger side. Aim has been to try and make off the shelf setup work. After several scrap yards just sending the wrong gearbox type, I got the passenger shaft from Astra H F23 1.7 diesel. Overall the shafts overall width should be the same as Astra H or SAAB 900 / 93. Got to buy specialised bearing carriers next. I believe the overall rear width could be +4 inches each side, with the current wheels and 8 inch tyres. This could be reduced with different wheels if needed, so I'm happy the car should look right. 20201122_154935.jpg 20201122_155138.jpg 20201121_153054.jpg 20201121_153105.jpg
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            • #81
              Now planning the engine mounts, which are not so easy. Will be tubular mainly. Got lazed cut plates now for front and rear mounts on the engine block. Going to get some 5mm steel and some 1.25" tubing bought, so some Welding can start in December. 20201114_152445.jpg
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              • #82
                Loving this build...it's gonna be mad!

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                • #83
                  Thanks. Like scrap heap challenge on steroids. Lets hope I can do something with it before petrol cars are banned..
                  Getting a reasonable enough body shell will be the hardest part, or maybe it should be rough and ready? Just functional. We will see...
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                  • #84
                    8mm steel engine mounting plates. Going to be tricky on the front with just this small turbo in the way.. 20201129_131757.jpg 20201129_131713.jpg
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                    • #85
                      Will have to drill and tap some of the existing bolt holes to M10.
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                      • #86
                        So, because I am using CVs and shafts from F23 GM box, I don't actually need to pay big money from Autograss CNC company for their alloy hubs. Just ordered the standard steel hubs and bearings as a complete unit. Good value at £25. Have offered them up to the rear arms and although I have different type of CVs either side ( 1 x saab , 1 x vauxhall), they fit. Just I need to enlarge the mounting hole on one side by about a mm all round and probably more on the Saab side.

                        I will probably bolt them on somehow and maybe add a couple of welds as well. Looking at the plunge on the shafts and these hubs, the track on the rear looks like it will increase by 1" both sides. So, the drive flanges are 4 x 100 pcd and my wheels are Caterham Ford 4 x 108 pcd. The best thing to do therefore is to source different 4 x 100 wheels with less offset, other wise I'll be looking at adaptor spacers and more track increase. So the decision is a no brainer. Best I get grinding and order the 2nd hub, now it looks feasible. 20201212_103038.jpg 20201212_103055.jpg 20201212_113615.jpg 20201212_113850.jpg
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                        • #87
                          Will probably look at Astra or Corsa rear discs and callipers after that. I think it will need a bit more rear braking with all that weight at the rear. I suppose I could also drill the drive flanges to 101.6 pcd and fit Mini wheels. 13" wheels appeal to me, but might have to look at a 15" wheel and tyre combo...
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                          • #88
                            Been reading up and if you class this as a mid engine, braking should be something like 55% front and 45% rear as opposed to FWD and RWD setups having rear braking between 20 - 30%. Seems the Astra H rear discs are cheap and 240mm, which with a calliper is doubtful to fit inside 13" wheels. Maybe looking at 15" wheels now or I suppose could have the discs turned down to 8.4" like minis. Much pondering and Ebay searching...
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                            • #89
                              Ground clearance for the 1st hub. Messy business with grinding wheel, but fits good. Rear arms have been drilled for Ford and other hub patterns. I think at least one bolt hole will line up. They also seems to have been painted blue, then red, then green and black. Be happy to sand blast them before welding takes place for Shock brackets etc. Looked at the 240mm Ford Escort discs I had left over, thinking I could have redrilled to 4 x 100, but they have too much inset and contact the rear arm, so that's a no go.20201213_125942.jpg 20201213_125951.jpg 20201213_131424.jpg
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                              • #90
                                OK, bad news on my daily driver ( Zafira B). Just before Christmas it decides to eat its clutch, slave and dual mass flywheel. That combined with earlier M32 gearbox fault, makes it not worth repairing. So will be on the search for a new car over the next few weeks, which is a pain, because would rather be working more on the project mini.

                                Anyhow, undeterred I have been offering up some new parts. Hub and bearing for other side arrived, so will be grinding over xmas to make that fit. Brake discs for Astra H 240mm solid rears arrived with some pads. They are 10mm thick and the 4 stud earlier versions I needed. Slight clearancing issue again. They have a chamfer on inside, but it needed to be larger by around 2mm, because the rear discs don't just fit what were front hub flanges. Went for 240mm because and earlier setup from an autograss car had squeezed calliper and 240mm disc combo inside 13" wheels. I thought it would be nice to have choice of 13 and 15" wheels for racing. Also, I did not want to step up to 256mm, which are vented and don't seem to fit or the next up is 264mm and I think only 5 stud option. 20201218_120253.jpg 20201218_120305.jpg 20201218_120414.jpg
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