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Historic Rally Clubman Project


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#1 rally1380

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Posted 16 September 2012 - 07:49 PM

Ok, so figured i might as well share my project with you lucky people.



Originally a 998, this 71 Clubman had a fair amount done to it by its previous owner - full respray in Rover Hurricane Grey, 1380 A series fitted with a Weber 45 (this was then changed to a HIF44), Minispares 7.5" disc conversion, Gaz shocks, and probably a fair amount more. He had it running on 13" superlights but they got ditched in favour of 10" Exacton's which i've become a big fan of!!!!


As things crop up during the build i shall explain more about the bits previously done on 'Barry' (as he was christened by previous owner...kinda stuck really) as there is a little story here and there!!


My plan is to turn 'Barry' into a Historic Rally car, to initially do Night Rallies and Historic Road Rallies, with the ultimate end goal of doing 'proper' stage events....if funds allow!!! The original colour of Aqua will be reinstated further down the line when time allows. You'll see the original colour here and there....as the spay job done on the car (by professionals i may add!!!) was terrible and is pealing in places!!!


Anyway, enough of the boring stuff, here's some pic's.......

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Did a production car trial over the summer (what there was of it!) and finished 5th overall and second in class....not bad for my first go, and considering the car that won overall was a 4x4 celica i think we did well.....and i got lost on one of the hills!!!!!! Note to self....always listen to navigator (wife!!!!). Cheers to Broughton and Bretton Motor Club for running such a great event.


The rally prep begins........

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First up, 6 point Safety Devices Roll Cage....



I really didn't want to cut the rear bins out as i kinda like them and they are one of the mini's little querks, but in order to weld in the spreader plates the bin had to get the chop. Made life a whole lot easier and if anyone is considering doing a cage...cut the bins. I'll be welding mine back in once plates are fully seam welded and painted.

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Just temporary fitted for the time being. 3mm spreader plates (exceeding MSA size spec's) tacked in to be fulled seam welded shortly.


Home brewed Oil cooler bracket was fabricated so cooler is kept nice a high up behind the grill out of harms way....fingers crossed!!!! All made of 3mm steel with captive nuts welded in so only one tool

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#2 jaydee

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Posted 16 September 2012 - 08:15 PM

Nice project! Good luck with the build!

#3 brad-the-bear

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Posted 16 September 2012 - 08:19 PM

looking good pal! another thread to be following :D

#4 minispaniard

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Posted 16 September 2012 - 08:20 PM

great to see another Mini being properly used!! I'm subscribing to this too...

a question about the spreader plates for the rollcage: is it MSA acceptable to weld them on the outside? I think Cooperman said once that that's the way he welds them and never had any problem at scrutineering.
The rollcage is the next move on mine and I could do with some clarification on this aspect.

keep up the good work!

#5 rally1380

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Posted 16 September 2012 - 08:54 PM

great to see another Mini being properly used!! I'm subscribing to this too...

a question about the spreader plates for the rollcage: is it MSA acceptable to weld them on the outside? I think Cooperman said once that that's the way he welds them and never had any problem at scrutineering.
The rollcage is the next move on mine and I could do with some clarification on this aspect.

keep up the good work!


I'm intending to weld plates on both sides just to tick all boxes and be safe. The reason i welded on the inside was because i figured in a bad roll over the impact would force the rollcage into the floor so if the plates are on the inside they are spreading that load alot better than if on the outside. But as cooperman says....he's had no problem with scutineering. The MSA bluebook is downloadable and has a section on rollcages if you want to have a look

#6 minispaniard

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Posted 16 September 2012 - 09:05 PM

it makes sense to me too... thanks.

#7 icklemini

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Posted 16 September 2012 - 10:34 PM

on the track cars they are checked at scrutineering and the plates do need to be welded on the inside.

#8 Tahiti Joe

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Posted 16 September 2012 - 10:57 PM

I've always welded mine internally, on minis, escorts and the odd scooby! :P

But too the OP, good looking project, sometimes I wish I had a clubman, that wee bit more room sure would be nice under the bonnet! :P Seems too be loads of rally builds cropping up at the moment! :D

#9 jaydee

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Posted 17 September 2012 - 01:27 PM

great to see another Mini being properly used!! I'm subscribing to this too...

a question about the spreader plates for the rollcage: is it MSA acceptable to weld them on the outside? I think Cooperman said once that that's the way he welds them and never had any problem at scrutineering.
The rollcage is the next move on mine and I could do with some clarification on this aspect.

keep up the good work!


I fi recall correctly Coops car has 'sandwitch' plates, one weleded inside and one welded outside

#10 TopCatCustom

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Posted 17 September 2012 - 03:26 PM

Is it not a bit excessive, welding 2x 3mm plates to a 0.9mm thick tin shell?! If it rips out with one, it will rip out with one either side! The area around the weld will be the most brittle which won't change whether there is one 1mm plate or two 6mm plates welded!

Have to say the car looks immaculate though, and your work looks very tidy :-)

#11 rally1380

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Posted 17 September 2012 - 05:04 PM

Is it not a bit excessive, welding 2x 3mm plates to a 0.9mm thick tin shell?! If it rips out with one, it will rip out with one either side! The area around the weld will be the most brittle which won't change whether there is one 1mm plate or two 6mm plates welded!

Have to say the car looks immaculate though, and your work looks very tidy :-)


That is a very good point and one that i will take on board and not waste any more 3mm plate.

Cheers for the positive comment, and if you think the car look immaculate now, just wait until i get round to the bodywork!!!

#12 rally1380

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Posted 17 September 2012 - 05:08 PM


great to see another Mini being properly used!! I'm subscribing to this too...

a question about the spreader plates for the rollcage: is it MSA acceptable to weld them on the outside? I think Cooperman said once that that's the way he welds them and never had any problem at scrutineering.
The rollcage is the next move on mine and I could do with some clarification on this aspect.

keep up the good work!


I fi recall correctly Coops car has 'sandwitch' plates, one weleded inside and one welded outside



Not sure on this one as when i asked his advice (although i've clearly not used it!!!...sorry pete!) he said he plated on the underside. I'm glad i went for the plating on the inside approach as welding upside down isn't easy and it hurts when a blob of red hot metal drops on you! >_<

#13 minispaniard

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Posted 17 September 2012 - 05:25 PM

sorry for the thread hijack!! ;D

I've sent a PM to Cooperman and asked him to contribute with his views to this thread...

#14 rally1380

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Posted 17 September 2012 - 06:27 PM

To clarify and conclude the whole Rollcage plate issue....or as i'm now calling it.....Plate-Gate!!!!!!


MSA bluebook states that the plate has to be 3mm thick and no less than 120 cm squared (for example 10cm x 12 cm) and can be attached as per drawings K13 to K18.....drawing K13a and K13 show plates welded to both inside and the outside.


Any chance we can now put the plate issue to bed???

#15 minispaniard

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Posted 17 September 2012 - 06:38 PM

YES... and sorry!!!




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