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92 City, My First Rebuild.

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#1 big-jay

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Posted 30 December 2013 - 11:21 PM

Hi all,

Been a member of this site for a while now and have decided to start my own thread.

Ive owned my 1992 Mini City for 2 years now. I got myself a job working at Landrover and saved for a few months in order to buy her. The reason i wanted a Mini was because my dad has been obsesed with them since a young age, and naturally, after going to a few mini shows and what not with him, i caught the Mini bug myself and just had to have one. She had been restored, (bodged, but I'll get to this later), before I brought her.

Here are some pictures of work being done before I purchased.

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Resprayed.

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All looks very nice and shiny, was over the moon with it and couldn't wait to get it home ! :D

Pictures of when I first got it home.

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Over the past two years I've made some changes/mods to her, stage one RC40 kit, cooper interior, centre speedo, deep dish wheels, angel eyes, new grille, 90% of the rubbers/seals changed, CD player, boot lining kit ect ect.

What ever she's needed she's had, no expense spared, regular servicing/cleaning/new parts and things like that as she is my pride and joy !

Some pictures of the changes I made.

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It's been great owning and driving this car for the last two years, everybody loves her and I get compliments from people saying how nice my car is all the time. The engine pulls strong and has never missed a beat as it is very low mileage for the age of the car and looks as if its been well maintained during its life. But unfortunately she has started to deteriorate over the last few months due to the poor primer/paint that was used. It's like my whole car has came out in a rash. There's bubbling everywhere and it seems to get worse at this time of year so I definitely want a respray sometime soon.

It didn't help that some little b*****d decided to drop a lit firework out of his car window, which unfortunately ended up spraying the whole drivers side of my car. The rear quarter wasn't to badly damaged and I managed to t-cut and polish the damage out, but the door paint was too far gone to save. So I decided I was going to flat it all back to the factory paint to see if that would cure the bubbling, and re-paint it.

So I flatted the door back and primered it, then left it a week or so as she was up for an M.O.T and I needed to get on with a few other bit and pieces. She needed two new tyres and not much else if I'm honest with you, just things here and there like a fuse or a bulb etc.

Brought these as a little treat for my self and my car as they caught my eye when I went to pic up my new tyres from Minispares !

88BC376A-C185-453D-9187-0B16B7A1BCF7_zps

Gaz lowered shocks and genuine hi-los, why not, I worked hard in the run up to Christmas ;-)

So, over the next few days I fitted them and got it up to M.O.T standard. The plan was to paint the door after but I thought, why not, I've got the paint and its a nice day, well, this is what happened...

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Where do I start :D Come to paint the door and realised the lip that attaches the a-panel to the wing had rotted away, so i decided to get the grinder out and chop out the old a-panel as my dad says there not to hard to change and are pretty cheap. Well this just went from bad to worse, chopped it out and came across huge metal plates that had been welded on to the flitch. So I decided to remove these plates and found all the nasties that lurked beneath it !!

Rot, Rot and more Rot !!

After seeing this I decided to start removing the flitch panel and upon finishing this I then realised I had several layers of metal where the floor pan is. So i decided to have a poke about and discovered I had several floor pans on top if each other. Got busy with the grinder again and found that the guy who 'restored' it had just slapped another floor pan over the top of the rotten one. A Proper Bodge Job !

I cut out the rotten floor pan, and then decided that, well, I've gotten this far so why stop here. She's got oversills which I hate because there water traps and were causing problems with water coming into the car. I had planned to remove them at some point, so I cut the over sill off and found that the guy had just plated either side of the rotten inner sill. The weld was so weak I could literally peel it off with a flat head screwdriver !! Not happy as you could imagine, seemed like it took more effort to Bodge it than it would have took to repair it properly !!

I removed all of the rotten inner sill and then discovered the rear quarter is rotten and was just filled with filler, not going to touch this yet though as, along with with the doorstep, this is keeping it rigid so I'll repair the above first then get started on this. So I now have a panel list as long as my arm and a ton of work to do, but what can you do, I guess that'll teach me for getting carried away with the grinder !

I think I've got the basics of welding down and my dads going to teach me some more over the coming days as his damn good with a welder, seeing as he also owns a Mini ;-). also I'm going to remove the bitumen under seal tomorrow as its nasty stuff and weighs a tonne ! I guess now its off the road Ill replace both sides as the passenger sides probably going to be just as bad as the drivers side is, can see this being a full on restoration now !

Will post an update tomorrow of how I get on.

Jay.

Edited by big-jay, 27 June 2014 - 07:14 PM.


#2 mattiek

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Posted 30 December 2013 - 11:47 PM

Great intro.....love the history behind you owning this car. It's a shame when people are lead to believe that a "restoration" has taken place - last time I looked in the dictionary, "restoration" didn't have the word "bodged" near it, lol!

 

I gather you are a true mini fan, and this will be a full rebuild now rather than just a few plates welded in here-and-there......good luck, plenty of photos please!

 

Will be watching, and welcome!



#3 jaydee

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Posted 30 December 2013 - 11:48 PM

You needed to brace the car before cutting the crossmember, minis are monocoque.

Now you need to take some accurate measurement before welding the new metal, or you'll end up with a twisted shell.



#4 big-jay

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Posted 31 December 2013 - 02:05 PM

Great intro.....love the history behind you owning this car. It's a shame when people are lead to believe that a "restoration" has taken place - last time I looked in the dictionary, "restoration" didn't have the word "bodged" near it, lol!
 
I gather you are a true mini fan, and this will be a full rebuild now rather than just a few plates welded in here-and-there......good luck, plenty of photos please!
 
Will be watching, and welcome!


Hi mattiek,

I'm glad you like it, this guy was a real bodger, but I'll definitely be restoring it properly this time around !

Also ill be sure to supply plenty of photos :-)

#5 big-jay

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Posted 31 December 2013 - 02:08 PM

You needed to brace the car before cutting the crossmember, minis are monocoque.
Now you need to take some accurate measurement before welding the new metal, or you'll end up with a twisted shell.


Hi jaydee,

Thanks for the advice, I'll definitely be sure to take some accurate measurements as the last thing I want is a twisted shell !

#6 big-jay

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Posted 31 December 2013 - 02:47 PM

Update guys,

Got the bitumen sound deadening off today, horrible stuff but not to hard to remove.

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Also I mocked up the new floor pan to see how it fitted, I don't think it's the right one for my car though so I'm going to scrap it and get the correct one, I know it's a waste and all but better to do it right the first time !

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What does everyone think of Magnum panels, I don't think there great if I'm honest !

Couldn't get too much done today as its New Year's Eve and all, trying to keep the noise down as I'm sure the neighbours are getting sick of hearing the grinder now haha ;-). I also ordered a few panels from M Machine today, doorstep, rear quarter repair panel and a crossmember repair section. Got to start some where and these will keep me busy until I can order the rest from Old Skool Minis after the holiday (3rd January I think).

Before removing the doorstep I'm going to replace the flitch and then brace the door with some steel box section, as I don't wont anything moving that shouldn't. I'm planning on repairing most of the other stuff first anyway to make it as strong as possible before removing it.

I also practised a bit of welding today, I don't think it went to bad if I'm honest with you, but I'm hoping to get your opinions on it.

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Got some decent penetration on it, so I'm happy (I think).

That's it for today, I might get some bits painted up tomorrow though, as I can't really do anything more until I receive some of my panels from M Machine. Hopefully they'll be here by the weekend so I can crack on with it !

Edited by big-jay, 27 June 2014 - 10:05 AM.


#7 big-jay

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Posted 03 January 2014 - 06:33 PM

Update,

Got the rest of the Bitumen sound deadening off from the passenger side today, found a few holes but I'm replacing most of the panels on this side anyway, when I've finished the drivers side, also found some more bodges, nothing new there then. No wonder my floor was always wet, half the patches he'd done weren't even fully welded, just tacked in and filled over with seam sealer !

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Picked a couple of panels up from Old Skool Minis today, flitch panel and an outer sill.

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Hopefully me and my dad can get started on welding in the flitch panel tomorrow, providing it doesn't rain too bad. Also I painted the seat anchors today, a little before and after -

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Painted them body colour for something different, really happy with how they came out, the picture doesn't do them justice. Going to use stainless nuts though as I'm changing most of the nuts on the car to stainless anyway.

That's it for now but hopefully will have something to update with tomorrow.

Edited by big-jay, 27 June 2014 - 10:06 AM.


#8 big-jay

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Posted 04 January 2014 - 09:54 PM

Update guys,

Fitted the new flitch panel today, pretty happy with how it came out, some pictures for you.

Chopped out the old (poor picture) -

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Kurust and weld through primer applied -

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Holes drilled for spot-welds and positioned into place ready for welding -

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Welded in and dressed (poor picture) -

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Got a few holes to fill in tomorrow and have got to make a plate to go around the top of the flitch as the metal was to far gone to save. Still got a long way to go but it's progress :-) !

Edited by big-jay, 27 June 2014 - 01:27 AM.


#9 big-jay

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Posted 09 January 2014 - 12:59 AM

Parts update,

Some of my panels from M Machine arrived today, Crossmember Repair Section, Rear Quarter Repair Section and a Doorstep.

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Should also be picking up a Inner Sill, Door skin, Wing and a Floor Pan on friday from Mini Spares, will post some pictures up when i have them in hand, but that's all for now, hoping me and my dad can crack on with it the weekend providing the weather isn't to bad !

Edited by big-jay, 27 June 2014 - 01:28 AM.


#10 domdee

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Posted 09 January 2014 - 10:02 AM

great project



#11 big-jay

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Posted 10 January 2014 - 04:07 PM

great project


Cheers pal !

#12 big-jay

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Posted 10 January 2014 - 04:23 PM

Parts update,

Went to Minispares today to pick up my panels, here's some pictures -

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Also picked up these ready for when I refurb the front subframe, Rebound Buffers and Poly Bump-stops.

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Will be getting some work done on the car tomorrow so will put pictures of progress up soon !

Edited by big-jay, 27 June 2014 - 10:07 AM.


#13 domdee

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Posted 10 January 2014 - 06:04 PM

D9AB7B4F-2B55-47BE-8ACD-BD317FAC381D_zps

 

is that your welders earth bolted on there?



#14 big-jay

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Posted 10 January 2014 - 06:12 PM


is that your welders earth bolted on there?

Yes mate, I sandwiched it between two bolts, not the best but it got the job done in the end, the clamps a bit dodgy haha !

Edited by big-jay, 27 June 2014 - 12:02 AM.


#15 skmulvany

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Posted 10 January 2014 - 07:16 PM

Great threaed, I have sneaking suspicion I'm going to learn a lot from this. Good luck with the build.







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