104 replies to this topic

[racingenglishcars]

Last night now that all the inner protectors are finished, it was just a question of mounting the front wings.

All clamped in place and aligned, for which we took good time for perfect fit.

We had to close the bonnet and therefore had to mount the car on stands and remove the spit.

 

IMG_20171031_193923 by frogeye61, on Flickr

 

IMG_20171031_193931 by frogeye61, on Flickr

 

IMG_20171031_193939 by frogeye61, on Flickr

 

Then spot welding. first a test spot on the bonnet gap area because we had to use the large c-grips there and couldn't close the bonnet. Not quite right, drilled out and did again. 

by the way, the inner wings don't stay straight unless the wings are welded on. They had to be forced a bit to one side before welding.

After the top seam for which there is no image, down the side seams on both sides:

 

IMG_20171031_200852 by frogeye61, on Flickr

 

Then the front seams from the inside. The car was turned on it's side for this - in with the spit, out with the stands.

 

IMG_20171031_203755 by frogeye61, on Flickr

 

The welder is heavy!

 

Whooptie.

 

IMG_20171031_203822 by frogeye61, on Flickr

 

Insted of rolling the car to the other side, we just worked above our heads and did the left side.

 

IMG_20171031_204350 by frogeye61, on Flickr

 

Whooptie.

 

IMG_20171101_072808 by frogeye61, on Flickr

 

And though it can't be seen so well, both wings are mounted and the entire front is straight.

 

IMG_20171101_072724 by frogeye61, on Flickr

[racingenglishcars]

Nice having a Sunday to work alone in the garage.

 

Saturday, since I am finished with the spot welder, I took it back to the garage club in Lyngby. I've only borrowed it for 9 months or so. But now there are all those small edges and corners that need finishing. Like these;

 

Front wings to front panel;

IMG_20171105_123352 by frogeye61, on Flickr

 

IMG_20171105_134707 by frogeye61, on Flickr

 

Windscreen surround to roof gutter:

IMG_20171105_123343 by frogeye61, on Flickr

 

Rear wing and inner wing to lower panel;

'IMG_20171105_141637 by frogeye61, on Flickr

 

IMG_20171105_133004 by frogeye61, on Flickr

 

Rear wing corner to inner wing;

IMG_20171105_133919 by frogeye61, on Flickr

 

Back panel to roof gutter;

IMG_20171105_123337 by frogeye61, on Flickr

 

I'm sure I have lots more boring pictures of these small welds but suffice to say they all got welded up today.

 

Example;

IMG_20171105_132343 by frogeye61, on Flickr

 

IMG_20171105_132901 by frogeye61, on Flickr

 

[racingenglishcars]

Another lovely Tuesday evening! Peter actually went home early citing headache from all the noise. We had two angle grinders running most of the time. Only one on the Mini, the other on a motorcycle sidecar.

 

However before all the noise, we thought it would be nice with a test fit of the Safety Devices rear bar with cross-brace.

IMG_20171107_175353 by frogeye61, on Flickr

 

Did anybody mention that theses are quite impossible to install in a completed car. And it doesn't have anything to do with the spit being in place. The four bottom feet of the are all too wide to fit past the B-post, in any possibility or any position-gyration. 

 

In the end it went in feet first. We used a rope to hold the forward feet together about 2 cm from rest point, and a cable-pull to pull the rear feet together nearly 4 cm. I suppose it would have been easier if there were no side bins but alas there are!

 

The front feet must pass between the side bins and door latch while the rear feet must pass further up on the B-post. This required violent compression of the rear bar's width. We also had to remove the windshield spacer which for some reason we have resisted. This implies that if it is done in a completed car, the windshield should be removed. This to allow the bar to go far enough forward that the front feet can go over the side bins.

 

IMG_20171107_180124 by frogeye61, on Flickr

 

Well, it's finally in place. It's a good thing we did it before paint as it would have scratched the heck out of the interior. We now have to put the mounting plates in, weld and epoxy paint before finally bolting the bar in place down INSIDE the side bins!. I guess in the end everything will be painted one colour. (Don't forget to tape the approval sticker before painting)

 

IMG_20171107_181531 by frogeye61, on Flickr

 

OK, so the angle grinder stuff.

 

IMG_20171107_202355 by frogeye61, on Flickr

 

These panels were covered with glue and insulation fibers.

 

IMG_20171107_202400 by frogeye61, on Flickr

 

Also the back seat. But they are all cleaned up now, awaiting sanding before epoxy primer.

 

IMG_20171107_202405 by frogeye61, on Flickr

[racingenglishcars]

Another Tuesday and more group work on the blue 64 Mini.

Peter got some seats a while ago and we test fitted the general position. I think I have a plan for properly mounting them now. More on that when the time comes.

 

IMG_20171114_180646 by frogeye61, on Flickr

 

I made a template of the left side petrol tank opening, then using that Peter cut a hole in the right side.

 

IMG_20171114_191750 by frogeye61, on Flickr

 

The fit is quite good when the tank is properly in place.

 

IMG_20171114_191839 by frogeye61, on Flickr

 

Fixed mounting of the roll bar implied tweaking a bit. The top corners aren't exactly the same side to side

 

IMG_20171114_192625 by frogeye61, on Flickr IMG_20171114_192634 by frogeye61, on Flickr

 

Half cm on left and 1.5 cm on right. And this was after compressing the legs trying to install it. 

No problem! Just a bit of cable pull. Mounted chain grips to the main bar on the left side to keep the cable in place;

 

IMG_20171114_191736 by frogeye61, on Flickr

 

and put a chain holder on the top right side.

 

IMG_20171114_191728 by frogeye61, on Flickr

 

I tweaked it a bit by pulling - hard, a bit more, and again a bit more.

 

IMG_20171114_192727 by frogeye61, on Flickr

 

In the end it was "much" better, that is to mean nearly the same distance on both sides. I had to take it out to bend the right side main bar a bit outward, just to relieve static stress. 

 

Actual positioning of the main hoop is primarily done by placement of the rear left foot. It is the one with the diagonal (triangulation), which generally can't be tweaked. 

 

IMG_20171114_214341 by frogeye61, on Flickr

 

Positioning of the main hoop (front) feet is done by tweaking the main hoop.

 

Despite what I wrote before, it will come out for painting.

Edited by racingenglishcars, 15 November 2017 - 02:42 PM.

[racingenglishcars]

Well, last night I decided to do something about the seat mount. Tim who will drive the car daily is a bit taller than I am and quite a bit taller than his father Peter, who initiated this build. The seat needs to be adjustable!

I suppose I could have started off with the standard front seat mounts, which are a very cost effective solution, but we really wanted something that would mount the seat adjuster a bit further back and since I would have to modify it anyway, I decided to just make some myself.

 

IMG_20171116_175252 by frogeye61, on Flickr

 

They came out quite well but way too long time. I won't do that for my own car. So far only one bolt hole along the length.

IMG_20171116_195107 by frogeye61, on Flickr

 

As can be seen above, there is only one mounting bolt on the seat bottom. I had cut off the other two height adjusters which all would have mounted the seat much too high. I'm considering cutting down the back legs. 

 

Now there are only questions of: F / R adjustment. Height adjustment. Angle adjustment. I will have to get Tim here to test it. 

Both supporting the rear seat legs at the bottom, and latching the seat down in the back are also considerations.

 

As it is, it does slide;

 

IMG_20171116_195232 by frogeye61, on Flickr

 

and tilt, which gives a very limited access to the back seat area (for not much more than small things).

IMG_20171117_080258 by frogeye61, on Flickr

[racingenglishcars]

A very rainy Tuesday and we didn't get much done on the Mini. Mostly the seat mounts. Aside from adjusting the seats for Tim, who didn't come to help, both in front height, rear height (for angle), we found that they were too close to the B-post. Again modifying the existing seat mounts by offsetting to the inside, 

 

IMG_20171122_073557 by frogeye61, on Flickr

 

and making two more for the other side.

 

IMG_20171122_073653 by frogeye61, on Flickr

 

The seat now appears to not conflict with the B-post and slides front and rear with no problem. It also still tilts.

 

IMG_20171121_214657 by frogeye61, on Flickr

[racingenglishcars]

Few images from week ago Tuesday evening, though quite a bit of work done.

Final adjustment of the seat with Tim the final operator - and steering wheel in place. The picture is not the final fit!

Welded force-distribution-plates onto the back legs. Otherwise the seat legs will put dents in the floor.

 

IMG_20171128_175913 by frogeye61, on Flickr

 

Made hold-down straps for both the right side tank in Peter's Mini and also for my own 64 Mini left tank, just because I didn't have one.

 

Cleaned rear trumpets including removing the completely rusted-on rubber cones. Had to use a Wood saw, lubricated with WD40. It worked a charm to peel the rubber back. Then used a grinder to relieve the rust-fit onto the cone. Then just a bit of clean-up and they're fine. Also cleaned and readied for paint at least one rear suspension arm. The brakes are already new so it's only paint.

 

More cleaning on the fuzz glued all over the back seat and parcel shelf, and all ready for prepping for epoxy primer which will happen next Tuesday.

Edited by racingenglishcars, 10 December 2017 - 05:49 PM.

[racingenglishcars]

Well, after all this cleanup it's starting to look good. 

Firstly, cleaning up the trumpets didn't do a lot of good since I asked Peter why he didn't just get some hi-los. So he pulled a set out of a box laying around. OK, enough for that!

 

After huge amounts of sanding and smoothing of the body, this Saturday was primer day. This is the first coat of epoxy, thinned well enough to go on with a "roller". I didn't think too much of the idea, but it worked a charm. A second coat, and a first coat where it isn't done yet, will happen after the holidays.

 

IMG_20171210_160329 by frogeye61, on Flickr

 

IMG_20171210_160345 by frogeye61, on Flickr

 

IMG_20171210_160337 by frogeye61, on Flickr

 

IMG_20171210_160359 by frogeye61, on Flickr

 

IMG_20171210_160605 by frogeye61, on Flickr

[racingenglishcars]

Meanwhile, my little red 64 got a few rust repairs in the engine compartment. First the engine steady.

 

IMG_20171203_184557l by frogeye61, on Flickr

 

IMG_20171203_191943 by frogeye61, on Flickr

 

IMG_20171203_194341l by frogeye61, on Flickr

 

IMG_20171203_195323 by frogeye61, on Flickr

 

Then a bit on front lower corner:

 

IMG_20171204_180709 by frogeye61, on Flickr

 

IMG_20171204_182936 by frogeye61, on Flickr

 

IMG_20171204_185520 by frogeye61, on Flickr

 

IMG_20171204_191620 by frogeye61, on Flickr

 

IMG_20171204_192125 by frogeye61, on Flickr

 

IMG_20171205_212221 by frogeye61, on Flickr

 

IMG_20171206_171253 by frogeye61, on Flickr

 

IMG_20171206_171918 by frogeye61, on Flickr

 

IMG_20171206_171711 by frogeye61, on Flickr

 

[racingenglishcars]

Yesterday Tim started with seam sealing the bottom... 

 

IMG_20171212_191031 by frogeye61, on Flickr

 

while Peter prepared the suspension components for epoxy black.

 

IMG_20171212_192858 by frogeye61, on Flickr

 

Once the suspension components were covered... 

 

IMG_20171212_203546 by frogeye61, on Flickr

 

IMG_20171212_203549 by frogeye61, on Flickr

 

there was some epoxy paint left over. 

 

Rather than it going to waste, Peter applied it to the bottom of the car, just not where the seam sealer is. The intention is that the bottom and engine compartment is black epoxy anyway, so one more coat should be fine.

 

IMG_20171213_080210 by frogeye61, on Flickr

 

We have slightly different road conditions here than the chaps in America with lots of salt in the winter. Since this isn't a trailer queen car, and intended to drive in the winter, it gets epoxy everywhere necessary and other rust prevention methods.

 

[racingenglishcars]

[Sorry, It's been a while what with Christmas, family visits, new tenant, and all that stuff. 

 

Peter got the bottom completely sealed and epoxyed the third coat We hope this is sufficient.

IMG_20180107_155208 by frogeye61, on Flickr

 

IMG_20180107_155157 by frogeye61, on Flickr

 

 

This also extends to all the seams around the car. There is very little body work to be smoothed, basically where some panels were joined or repaired, but with all this epoxy paint just about everything must be smoothed by hand before paint.

IMG_20180107_154957 by frogeye61, on Flickr

 

IMG_20180107_155013 by frogeye61, on Flickr

 

IMG_20180107_155005 by frogeye61, on Flickr

 

IMG_20180107_155022 by frogeye61, on Flickr

 

This car is not a show car and will not be body colour all the way around. (Likely dark blue or purple) The bottom is pretty much completed the way it is. So now the suspension will be assembled and installed to facilitate rolling to the paint shop.

The rear subframe is powdercoated and assembled:

IMG_20180102_211710 by frogeye61, on Flickr

 

We also have an old set of wheels

IMG_20180106_122828 by frogeye61, on Flickr

 

 

The front subframe will be assembled this evening, being the usual Tuesday evening work night.

 

[Vinay-RS]

This car is coming along nicely. Those old D1s are a cool find.

[racingenglishcars]

So, it's been a while. What with Christmas and a visit from my son who lives near Virginia/W.Virginia border, My trip to America for the Grand National Roadster Show in Pomona Ca, A trip to India for electronic hardware configuration on a test facility, a trip to Florida with the family, and I just forgot to post for a couple months.

 

Between all that, Peter and I managed to get the rear suspension assembled with many new parts, bushings, Hi-Los, brake pipes, shoes etc. Notably with liberal amounts of copper grease, apparently to help prevent future rusting of the fasteners.

IMG_20180213_211346 by frogeye61, on Flickr

 

We then found time to assemble the front suspension.

 

IMG_20180220_211711 by frogeye61, on Flickr

 

The one in the back is for my own car painted with epoxy paint, while Peter's subframes are done with power-coat.

 

Peter had not been at our Tuesday work evening for several weeks. While he was away in Greece one time, I mounted the steering rack.

IMG_20180309_175739 by frogeye61, on Flickr

 

The next week I got another friend to help put the subframe in place then take the car down and set it on it's own four.

IMG_20180313_193448 by frogeye61, on Flickr

IMG_20180313_205108 by frogeye61, on Flickr

 

With steering mounted I didn't have the key, so by the next week Peter had emailed me the location of the key so I could actually turn the steering wheel. (sorry purists, no original steering shaft on this one)

Peter has since been back and mounted the front subframe top bolts while he delivered the engine/gearbox for some work.

 

 

So since the Mini has wider wheels than standard, and there are laws about covering the tires, we had to add wing extensions. A cheap set, difficult to install

 

IMG_20180521_195229 by frogeye61, on Flickr

 

We made a few repairs to the non-new replacement parts, meaning doors and boot lid.

 

IMG_20180521_202017 by frogeye61, on Flickr

 

The wings were GRP bonded to the wings.

 

IMG_20180521_220150 by frogeye61, on Flickr

 

With a set of wheels, it's looking OK. This includes the set of long steering arm joints so the wheels point straight.

 

IMG_20180605_191446 by frogeye61, on Flickr

 

The car now rolls for the first time out of the garage in about 21 months.

 

IMG_20180605_192112 by frogeye61, on Flickr

 

It is on it's way to the paint shop as I don't think I can do it justice in my little garage, and I don't want to get paint all over everything.

 

IMG_20180605_194335 by frogeye61, on Flickr

 

I had been fitting new cam bearings in the engine

 

IMG_20180524_203026 by frogeye61, on Flickr

 

for a MD266 cam.

 

IMG_20180518_061017 by frogeye61, on Flickr

 

So on Constitution day here in Denmark, while Peter drove the car to the paint shop, Tim and I cleaned the engine thoroughly both inside and outside

 

IMG_20180605_183438 by frogeye61, on Flickr

 

IMG_20180605_185103 by frogeye61, on Flickr

 

Then I taped it up and painted it.

 

IMG_20180605_212654 by frogeye61, on Flickr

 

In the meantime, Tim cleaned up the starter and generator so I could paint them too.

 

IMG_20180605_212716 by frogeye61, on Flickr

 

IMG_20180605_212721 by frogeye61, on Flickr

 

 

Here we finally got around to assembling the motor

 

IMG_20180703_194510 by frogeye61, on Flickr

 

It should all be ok, but everything is tested anyway. A couple marginal clearances cleaned up and the short block is done

 

IMG_20180703_211525 by frogeye61, on Flickr

 

Not too much this week. Finally got a correct transfer gear so put these two major components together. Also fiddled with the speedo drive and bearings.

 

IMG_20180710_202656 by frogeye61, on Flickr

 

Then cleaned up the third major component and installed it also.

 

IMG_20180710_211554 by frogeye61, on Flickr

 

It's not the final valve cover.

 

[minimissions]

Some awesome work on this car. It makes me wish I kept my mk1 now. gutted....

[racingenglishcars]

Finally, some recent pictures of this project:

 

Tim01 by frogeye61, on Flickr Tim02 by frogeye61, on Flickr Tim03 by frogeye61, on Flickr Tim06 by frogeye61, on Flickr Tim07 by frogeye61, on Flickr Tim08 by frogeye61, on Flickr Tim09 by frogeye61, on Flickr Tim05 by frogeye61, on Flickr Tim04 by frogeye61, on Flickr