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1972 Mini Clubman Estate [Project Stitch]


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#1 HollyBaby

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Posted 11 February 2012 - 08:15 PM

Note: This is a joint project between me and my dad (currently more so my dad for the obvious ailment of being away from home at the moment!) So much of the rebuild blog will be written from my dads side of things just before anyone thinks I'm writing in a strange form - especially for a girl! And the big manhands in the photos haha..
Never the less... here we go!

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Checking back, I've now had this car 7 years (really?) and it's not getting much closer to being on the road. In fact I think it's been in the garage for about three years...

Anyway, here's this week's work (I'll post the older work later!) I did the front end in the winter of 2002, and fitted the engine. Which we subsequently robbed back again for Evy! Well my plans were to put a K-series in - right now the engine choice is uncertain, but let's see what transpires. And recently I had to rob a top arm for Gigi. Anyway, I need to move this car, so getting wheels back on were first priority. I managed to extract the seized top arm shaft eventually with a very big hammer and lots of heat & penetrating fluid, and refitted it with a temporary shaft. So I could drop some hubs on and get the front back on its wheels.

I didn't want to move it yet though, because I know that the rear floor and door pillar have parted company, and I want to get that reattached before it goes anywhere. And that's where the problems began...
I have a rear step plate, so I began by drilling out the spot welds from the upper support bar and removing that.

Here's some pics of what I have to contend with:





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Wheelarches have seen better days. I think I'll be investing in new ones there. They're not hidden like in a saloon!


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The condition of these subby mounts is worrying as that part seems to be NLA?


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Next I looked at the nearside lower corner, which had been filled with plate backing (no welding involved!!!) It was falling off, so I decided to fit REPAN041 from Somerfords. Carefully measure (what's left!), mark it off, cut the wing (the remains can be seen on the floor below!)

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Offer up repair plate - it quickly becomes obvious that it's wildly inaccurate! Beggar. It would be OK if I put wodges of filler on top, but that's not my style. I offer up the corner plate below it, and things get worse - nothing seems to line up:


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So, HELP!!!! Can anyone please be kind enough to post detailed accurate measurements of this area, and the door aperture, so thet I can get it all fitting right? I just don't have enough metal to guess from right now, and as an early CE it's too good to spoil.

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We've now started work again as Holly wants the car on the road. New arches were purchased at a show in the summer, and I've now priced up a whole list of panels and parts - a scary list of £700+ even before we get onto the interior, wheels & tyres, and an engine!! I'm going to do this properly, so I've now decided new rear quarter panels will have to be fitted - there's just too much damage to repair well.

The plan now is to fit a Nissan Micra engine, which is a distant relation of the A-series and even comes in 998 or 1275. That will give more power, a 5-speed box and modern engine economy & reliability.

The paintwork is going to be blue, probably two shades, one of which will be Surf Blue, to match Disney's "Stitch" character, which is Holly's favourite.

Front screen removed - it will need a new one as it's badly scratched plus it's an original Triplex toughened - not even laminated!




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Anyway, today I started to strip the rear windows, having removed all the seats last week.



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The rear sliding windows are going to be replaced with one-piece fixed sections (how is yet to be decided!) so I just ripped the old channels apart - not that that took much doing anyway! The frames, which I was a bit worried about, came out quite easily and are OK to be renovated. If I decide to use them - not entirely sure how to refit them with fixed glass. I think I'd like to do a modern-style flush bonded window - don't think it's been done before, so some trailblazing to do!




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The bottom window rails are a bit rough - the seam with the quarter panel has swollen, a sure sign of rust behind, so I may have to replace these too.

Need to get the panels to do the floor now and roll the car over to do all that underfloor welding.

Edited by HollyBaby, 11 February 2012 - 08:17 PM.


#2 minimissions

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Posted 11 February 2012 - 08:51 PM

Yay another estate being rebuilt :)

#3 Peskett

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Posted 11 February 2012 - 09:17 PM

As above, good to see another estate rebuild.Are you keeping the wooden trim?

#4 HollyBaby

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Posted 11 February 2012 - 09:19 PM

As above, good to see another estate rebuild.Are you keeping the wooden trim?


I'm afraid not, I may upset some traditionalists as we're removing the wooden panel and going fairly custom with him! We shall have to see hehe

#5 Jordie

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Posted 11 February 2012 - 09:32 PM

Looking good, dont worry its your car so do as you please. I painted my wood to give a black "racing stripe" type effect lol

Why not replace the rear windows with van panels? *cough* http://www.theminifo...-special-price/ *cough*

Good luck with it, PS ive got the same rust in the NSR corner of mine, looks just like your photos at the minute.

Jordie

#6 HollyBaby

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Posted 11 February 2012 - 09:35 PM

Looking good, dont worry its your car so do as you please. I painted my wood to give a black "racing stripe" type effect lol

Why not replace the rear windows with van panels? *cough* http://www.theminifo...-special-price/ *cough*


PapaB is toying with the idea of replacing the wood with something more sustainable! Just trying to figure out what to do with the two tone paintwork =\ may also be getting some airbrushing going on haha! Oh shiny!

Erm afraid not a FG fan! Wanting one solid window, seen it rarely on estates and not seen it done how we want it so it's going to be a little naughty!

#7 Jordie

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Posted 11 February 2012 - 09:38 PM

Shouldnt be too hard to bond a modern type window in there, like the ones used in transit conversions. Finding the glass the right size and shape will probally be the hardest thing.

#8 HollyBaby

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Posted 11 February 2012 - 09:42 PM

Think there are a few places we can get some cut down?

Just a lovely huge list still to get HERE if anyone is able to help haha!

#9 MrBounce

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Posted 11 February 2012 - 09:45 PM

Looks like it's gonna be a good one. Following this ;D

#10 asahartz

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Posted 11 February 2012 - 09:49 PM

Sometimes tradition and originality is right, sometimes it's good to go custom. Most of my cars are traditional at first sight but have subtle (or not so subtle!) mods under the skin! So this one will be fun to play with - I want to make it as modern to drive as possible but still be a Mini.

As for estate, it stays estate but with tweaks. The wood trim itself is knackered but the chrome is OK - might keep that, but the wood is gone. I've been part of the Clubman Estate Register for a long time but have never actually taken an estate out with them! We have clubman, GT, roundnose, Elf, and Holly's bro now has a pickup - most of the Mini family really!

#11 Burnard

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Posted 11 February 2012 - 09:51 PM

I'm afraid not, I may upset some traditionalists as we're removing the wooden panel and going fairly custom with him! We shall have to see hehe


This is the way forward! infact, the more upset the better! :lol:


You should be able to get some glass cut, or polycarbonate with marguard (will be cheaper) to the right size quite easily.

By way of sealing it, there are a few options, you can weld on a slightly thicker lip and bond it on, then hide that with a nice bit of black graphic round the edge, which is basically what modern cars have, except the black cover is bonded to the glass.

The other option would be to round off the corners to the same sort of radius as saloon rear quater pannel windows and use that type of seal, can be bought from phoenix supplies, if you ask them they will give you the right stuff before they cut it up for the saloon sizes.

#12 blue blood

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Posted 12 February 2012 - 08:00 PM

Finally started a build diary after a lot of blogs I see i'll watch this one :) Instead of the wood trim carbon fibre might look very nice .

Regards Blue

#13 HollyBaby

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Posted 12 February 2012 - 08:21 PM

A bit more done today!

Stripped the rear window the other side.

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Removed the dash top.

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Removed the rear doors. The back edge of the floor needs replacing but I already have this section. I've already removed the boot floor support.

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Removed the remaining chrome trim from the rear quarters.

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I just need to cross-brace the rear door opening and the seat back support then I'll be able to start work on repairing the floor as soon as I get the side repair panels and cross member. Need to order them! Car will be rolled on its side then.


Edited by HollyBaby, 12 February 2012 - 08:23 PM.


#14 samsfern

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Posted 12 February 2012 - 09:12 PM

Wow, progress, looking good! Have you decided on colours yet?

#15 ukshadow

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Posted 12 February 2012 - 09:44 PM

looking good. I to am looking into setting in the side windows on my estate i currently have black perspex with the frames but i am trying to workout a way of fillting them in without the frame.




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