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1999 Cooper Sportspack @ Mill Road Garage


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#16 Rocket.

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Posted 24 November 2015 - 08:42 PM

Doesn't look at all bad compared to other sports packs



#17 Ben_O

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Posted 24 November 2015 - 08:44 PM

Doesn't look at all bad compared to other sports packs

Agreed.

 

I was quite surprised. There is some work required on the windscreen frame panel and the front end but they will be done another time.



#18 toplessmini

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Posted 24 November 2015 - 09:41 PM

I purchased it because I intended to replace it.

I've had it for more than 2 years, just sat in the garage waiting for someone to fit it. Turns out it was very much needed......... :whistling: 


Edited by toplessmini, 24 November 2015 - 09:42 PM.


#19 James_eaton_thewholething

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Posted 24 November 2015 - 10:22 PM

So the world of bodges continues lol. At least now it will be done properly and will be one super solid car when finished

#20 Ben_O

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Posted 24 November 2015 - 10:24 PM

So the world of bodges continues lol. At least now it will be done properly and will be one super solid car when finished

That's the plan :-)



#21 Ben_O

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Posted 25 November 2015 - 07:02 PM

So with the strip out complete, it's time to to start putting metal back.

 

But before that, i needed to remove the valance closers and arch tubs. I am going to do one side at a time so that i can use the subframe to line everything up perfectly.

 

I started by drilling the spot welds through the boot floor to remove the closers. As i started splitting the layers, it became apparent that there was quite a lot of corrosion in this area

 

oeOVzE5.jpg

 

And on closer inspection, it was too far gone to save

 

rfX7Vw6.jpg

 

This was all hidden under the factory sealer....

 

So i stopped where i was and changed plan. As a result, this happened..

 

LptikkO.jpg

 

At this point i also removed the subframe mount stiffener  so that i could remove the remains of the floor behind it. This is so that i can get an accurate template for the panel i need to fabricate.

 

I cut an oversized piece of steel and then cut and turned down the edge to follow the arch tub. Here it is in place ready to mark out for trimming

 

egbm62C.jpg

 

0mFBuCk.jpg

 

Before going any further, i disconnected and removed the ECU as well as disconnecting the Alternator. Just in case of a surge.

 

BXM59zA.jpg

 

And then after further trimming, it was clamped in place and tacked. 

 

UqrIlQS.jpg

 

Once i checked everything, it was fully seam welded and cleaned up

 

QCHcpt3.jpg

 

With this done, i could now remove the old arch tub as this was only left to act as a guide for the new floor section

As usual, it had to come out in pieces due to the way it is welded

Here is the spot welds found and marked out

 

rTcGek5.jpg

 

And then quite a while later, we have a pile of rusty metal on the floor.

 

QClhDwH.jpg

 

Some cleaning up of edges came next. Some will have to be re-fabricated though due to corrosion

 

Exdo3au.jpg

 

HarCbsR.jpg

 

Next, i cut and shaped the bumper lip extension of the floor repair to the correct shape in preparation for making up a new bumper lip section for the lower rear panel

 

vcJ9LDQ.jpg

 

And here is the rough out of the repair piece clamped in place for trial fitting.

 

rPPdRdH.jpg

 

Quite a few sections will need replacing due to corrosion. I will do this in sections.

 

After final trimming, it was tacked into place

 

Isc2lFD.jpg

 

And then seam welded and partially ground down

 

fhca3Fq.jpg

 

Next time, i will be doing the same but the other side in preparation for the new panels. There won't be an update tomorrow as the Mini won't be being worked on again now until Friday.

 

Cheers

 

Ben



#22 wingnut

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Posted 25 November 2015 - 07:44 PM

Ben,you are a talented man



#23 Ben_O

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Posted 25 November 2015 - 07:59 PM

Ben,you are a talented man

Thankyou sir!



#24 James_eaton_thewholething

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Posted 25 November 2015 - 10:03 PM

I've missed regular updates of your work i really like seeing how you fabricate parts 



#25 Ben_O

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Posted 25 November 2015 - 10:07 PM

I've missed regular updates of your work i really like seeing how you fabricate parts 

Cheers James.

It's nice to get back on the Mini's since mine has been laid up



#26 James_eaton_thewholething

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Posted 25 November 2015 - 10:15 PM

its nice that the customer has allowed you share the rebuild too at least its going to be another saved mini



#27 Carlos W

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Posted 25 November 2015 - 10:29 PM

its nice that the customer has allowed you share the rebuild too at least its going to be another saved mini

A good way of him getting updates too 



#28 slidehammer

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Posted 25 November 2015 - 10:30 PM

I am impressed with the speed of progress, it take me longer than that to get the overalls and kettle on!



#29 James_eaton_thewholething

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Posted 25 November 2015 - 10:34 PM

 

its nice that the customer has allowed you share the rebuild too at least its going to be another saved mini

A good way of him getting updates too 

 

that is true saves them having to take loads of trips to check progress



#30 Carlos W

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Posted 25 November 2015 - 10:50 PM

 

 

its nice that the customer has allowed you share the rebuild too at least its going to be another saved mini

A good way of him getting updates too 

 

that is true saves them having to take loads of trips to check progress

 

You read so many stories of people finding the garage has had the car for months, been taking instalments but nothing happening.






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