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1999 Cooper Sportspack @ Mill Road Garage


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#1 Ben_O

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Posted 23 November 2015 - 06:29 PM

Hello All.

 

This is to be a thread documenting some body repair and MOT work we are undertaking at Mill road garage on the Isle of Wight on behalf of a fellow TMF'er.

 

We had the car recovered to our workshop this morning for inspection before work commences.

 

Initially we quoted for work to the sills as it currently has cover sills fitted but further inspection was required as well as putting it through an MOT to see if and what else needed doing as the car has been off the road for 2 years.

 

Here is the car as it arrived just prior to performing the MOT test.

 

cMmweMK.jpg

 

Apologies for the blurry photo but i didn't realise it was until i uploaded it to the computer :(

 

So after inspection of the car, we have found some more corrosion to the rear arch tubs, the rear valance and closing panels which unfortunately contributed to the MOT fail.

 

It's a lovely little Mini and certainly attracted a lot of attention from staff in neighboring units and will soon be returning to the road.

 

Work has started on stripping out the car so it is well under way.

 

I will update this daily as progress is made.

 

More tomorrow.

 

Cheers

 

Ben



#2 Carlos W

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Posted 23 November 2015 - 08:42 PM

I'm sure it'll be excellent mate



#3 toplessmini

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Posted 23 November 2015 - 09:00 PM

I just wish I could have washed it before it was taken away, bloody clutch........



#4 James_eaton_thewholething

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Posted 23 November 2015 - 09:02 PM

Looking forward to seeing updates

#5 Ben_O

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Posted 23 November 2015 - 09:23 PM

I just wish I could have washed it before it was taken away, bloody clutch........

No worries, It will be washed and polished before it goes home.

 

And the clutch is now working. The arm was stuck so the clutch was stuck on. we freed it up but it will require cleaning up properly before It goes anywhere. I will sort that for you though.

 

Shame we freed it up after the MOT. You should have seen us trying to push it on and off of the rollers :lol:



#6 Steve220

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Posted 23 November 2015 - 09:45 PM

Hopefully the remnance under the oversills won't be too horrific, the car overall looks in great condition! (Despite the shakey pic!)



#7 Ben_O

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Posted 23 November 2015 - 09:56 PM

Hopefully the remnance under the oversills won't be too horrific, the car overall looks in great condition! (Despite the shakey pic!)

I know exactly what it will be needing as i stripped it out this afternoon. :-)

 

Ill pop some pictures up tomorrow



#8 Ben_O

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Posted 24 November 2015 - 07:09 PM

Work recommenced today on the Cooper.

 

The First job was to carefully remove the Sports Pack arches so the front wheels were removed in turn to access the fixings.

 

nvNIGPs.jpg

 

As you can see, i also removed the rear ones after stripping out the interior.

 

Then the bootlid, bumper, battery, fog light and fuel tank was removed

 

sZO4Aem.jpg

 

And then the wiring harness was passed through the inside of the car and bundled up out of the way leaving the inside nicely stripped out

 

98EKr1P.jpg

 

Next up was removing the rear subframe so the exhaust was removed, the brake lines and handbrake cable were disconnected and the subframe mount bolts were cracked off.

Of course, the wheels were removed first.

 

A bit of a struggle with the seized bolts later and the frame was ready to come down.

 

7GSo2Ub.jpg

 

Using a combination of the ramp jack and a couple of axle stands, the frame was free of the car.

 

Aoqck87.jpg

 

And out

 

25kovND.jpg

 

This subframe is heavily corroded as you can see in the following photos.

 

ehRwbmV.jpg

 

KnCofiY.jpg

 

But a new one has been provided by the customer along with all new parts to fit to it.

 

2GZY2Yi.jpg

 

So with the strip out completed, we can start to look at the work that is going to be needed.

 

This car has had cover sills fitted in the past

 

o0kEyB7.jpg

 

They are in places, fitted over the existing sills, and inside the companion bins, sections of the inner sill have been cut away and not replaced with any steel at all.

 

LoXMTnW.jpg

 

7rc3Yz7.jpg

 

Besides this, cover inner sills have been fitted and just seam welded around the edges to the seat cross members. Not a particularly tidy job but i suppose it served it's purpose in the past.

 

96Lyp5d.jpg

 

So new full inner and outer sills will be fitted. I will also fabricate new seat crossmember ends to replace the old ones.

 

Next we have the rear arch tubs which are too far gone to repair so a pair of new ones will be fitted.

 

One side

 

t3Ysz29.jpg

 

And the other

 

GN0ZJBu.jpg

 

Then onto the rear end, the boot floor will be repaired as well as a new rear valance and closing panels

 

ZsuA55g.jpg

 

5rMg0ac.jpg

 

I shall also be repairing the lower rear panel to sort out some heavy corrosion on the bumper lip.

 

The heelboard doesn't look to bad and seems solid. There will be some repairs needed on the ends but overall pretty good

 

f042dG7.jpg

 

JeLCTec.jpg

 

And now to start the cutting.

 

first to go was the rear valance.

 

xxQmDIq.jpg

 

I have also cut out portions of the rear panel bumper lip to replace.

 

A609zjq.jpg

 

The boot floor will need some repairs as it has been repaired in the past using wire mesh and body filler

 

yc0xw1m.jpg

 

The entire bumper lip is crusty so It may need more repairs than i thought. I will also be fitting a full width repair panel on the back of the boot floor.

 

So here we are for today.

 

wjpx7X6.jpg

 

Tomorrow will see the release of the old crusty rear arch tubs as well as the valance closers and the repairs to the bootfloor and rear panel will begin.

 

Cheers

 

Ben



#9 Steve220

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Posted 24 November 2015 - 07:32 PM

Christ, fair bit of rust! Is that a new genuine sports pack rear subframe?

#10 Carlos W

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Posted 24 November 2015 - 07:34 PM

Not bad for a day's work mate

#11 Ben_O

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Posted 24 November 2015 - 07:47 PM

Christ, fair bit of rust! Is that a new genuine sports pack rear subframe?

It looks like it to me.

 

The customer ordered it and supplied it to us.

 

Cheers

 

Ben



#12 Ben_O

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Posted 24 November 2015 - 07:48 PM

Not bad for a day's work mate

That wasn't all day mate. I spent quite a bit of time with paperwork and on the phone ordering parts.



#13 slidehammer

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Posted 24 November 2015 - 07:53 PM

Interesting stuff, still in pretty good shape for a Sports Pack though. Looks like you have got to it in time to turn it around. Keep the updates coming



#14 toplessmini

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Posted 24 November 2015 - 08:26 PM

Christ, fair bit of rust! Is that a new genuine sports pack rear subframe?


Yep.....

#15 Steve220

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Posted 24 November 2015 - 08:33 PM

 

Christ, fair bit of rust! Is that a new genuine sports pack rear subframe?


Yep.....

 

 

Out of curiosity, where did you manage to source one? I've struggled to find anyone with them in stock.






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