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Big Plans For A Little Car


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#1 sg_frost

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Posted 08 April 2018 - 10:08 AM

Having recently completed the mini van shown below to as original as possible I decided it was time to do something a little different. I managed to find this little saloon for a bargain price within a few miles of where I work. It came with plenty of new panels and plenty of rust in some areas. The car is complete other than a carb which is not likely to be needed. 20 years ago I built a sports pack arched turbo mini and the urge to build another has always been there. A Haynes roadster with a 2.8 BMW lump in it and two rally cars have been built in the meantime. This one has got the grey matter working already, its nowhere near needing re-assembly yet, but so far I have bought a disk brake conversion for the front and a aservo pedal box.
The plans for this build include.
Deseamed corners and bumpers
Smoothed bulkhead with nothing mounted on it, master cylinder to be inside the car.
Smoothed inner wings with all holes blanked except radiator cooling areas.
Smoothed doors with handles removed and remote opening.
Internal boot hinges
Wide arches. Either sports pack or zeemax type kit
Disk brakes all round
Twin cam head on a series block
Change of lights somehow.
Either twin tanks or filler moved to inside the boot
Heated leather electric front seats and rear seats trimmed to match

The question is, how much will get done or will it end up on eBay as another incomplete project? Who knows?Attached File  69BEAFB4-E8C4-4046-9392-5EDBF55FBC7A.jpeg   61.69K   7 downloadsAttached File  1680ECEA-3520-4E36-8875-B5E3B32BBC81.jpeg   31.26K   5 downloadsAttached File  46621F20-E929-463A-951F-D9E6AC7158C3.jpeg   69.26K   7 downloadsAttached File  C7BD38C8-43F8-4B1B-9724-551C36FC54E9.jpeg   26.84K   5 downloads

Edited by sg_frost, 12 April 2018 - 08:49 PM.


#2 sg_frost

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Posted 08 April 2018 - 10:11 AM

Bulkhead modifications taking place, need to do something with the hinges to open the bonnet further. Had a pair of quick release ones on the turbo but they were a pain in the butt trying to get the bonnet on and off without scratching the rear corners.Attached File  8DF2449E-5949-431E-87AE-444BF08D9DA2.jpeg   62.9K   6 downloadsAttached File  28AD2A41-2145-4309-BB4E-87349936EC08.jpeg   58.9K   5 downloads

Edited by sg_frost, 12 April 2018 - 08:49 PM.


#3 sg_frost

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Posted 12 April 2018 - 08:48 PM

Wanting to not smash my head on the bonnet as usual, I thought I would investigate a method of modifying the hinges. My last mini turbo had quick release hinges but to align them up on the pivot bolt was a bit tricky and could scratch the scuttle. I toyed with the idea of making them quick release from the bonnet rather than the body but couldnt decide on how to do it. I them came across some articulating hinges that allow the bonnet to open vertically and set about making my own.
Completely made from stainless, a bit more polishing and sorting out sharp edges and they should look ok.Attached File  F9C89AB9-CBD9-48B3-9C7D-C4C8E6358A38.jpeg   46.68K   2 downloadsAttached File  DA267490-6DD5-40E4-B890-9EE065D961AC.jpeg   45.99K   3 downloads

#4 Chris.Williams

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Posted 13 April 2018 - 12:19 AM

Be following this to see where it leads.

#5 johnR

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Posted 13 April 2018 - 10:21 AM

great project - I'll be interested to see how you deal with the challenges!



#6 sg_frost

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Posted 15 April 2018 - 08:35 AM

Attached File  2F3AB0BE-ECCE-4BBA-A0D9-8F5E8A9E56F1.jpeg   62.14K   5 downloadsAttached File  FA4BE984-55B8-4DB0-B789-1926267413A0.jpeg   57.22K   5 downloads
More progress made today, front end looking good but only temporary held together. Previous owner has replaced drivers door hinge panel, Im not convinced its in the right place so need to adjust that next.
Happy with the way the bulkhead is going, just sort the ends out and weld the top up next. The bulkhead stiffener on the N/s has done the usual thing of corroding behind and swelling so this is going to have to be replaced.

#7 sg_frost

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Posted 15 April 2018 - 07:19 PM

More work today, drivers inner wing getting there. Lower section that the previous owner had drilled through all the spot wells replaced and most of the holes filled. Cant seem to find where I put the plate for the big air intake so will have to make another.
Confirmed the flitch repair panel is in the wrong place, the door hinge piece had too much material on it and the flitch was simply put over the top. I think it will be simpler to replace the flitch again, his welding is not the best Ive ever seen.Attached File  80742270-33CA-4B37-9AEF-F89C576DD18C.jpeg   19.44K   7 downloadsAttached File  E04C9054-19F4-41BB-86FC-A7061E3023C7.jpeg   41.24K   8 downloads
Etch primer used to keep it rust free whilst the rest of the work progresses. Sort the door post and under bonnet before finalising the front end and then onto the floor.

#8 minimissions

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Posted 19 April 2018 - 05:47 AM

I like the fact your doing something different with this, keep the pics coming.



#9 sg_frost

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Posted 16 June 2018 - 11:33 AM

Slow progress lately, engine bay looking better, but engine plans are coming along.

The master cylinder holes on the passenger side, the triangular hole in the stiffener on the driver side and the hole in the bottom of the inner wing on the passenger side have also gone. The front end has been welded on too, need to get updated pics.

Has anyone seen the price of a conversion kit to put a 16v motorbike head on a A-series?.
So with bit of research I found out most of what I need. Just to collect the 1275 this week as this is a mock up on a 998. I have to make the pulleys fit and then make back plates to seal the oil from coming out.

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#10 1330RG

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Posted 18 June 2018 - 11:27 PM

Like that this is going in a different direction to most. Nice one bud

#11 sg_frost

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Posted 22 August 2018 - 07:29 PM

Slow progress lately, had to take the family away on holiday. Before I went I made some progress on the engine. Head has been sent away for welding and is now ready fo collection along with modified pulleys for the block.
The block has ha
d the face blanked off and then machined flat. Not 100% happy as the top threads caught on the machine and is chipped but should not cause any issues.
Gearbox has been stripped and vapour blasted. Found one bearing to be completely destroyed. Can’t believe the price of new bearings, and should really replace the synchro rings whilst I’m in there.

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Edited by sg_frost, 22 August 2018 - 07:30 PM.


#12 Avtovaz

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Posted 24 August 2018 - 12:13 PM

Ronnie won’t pass this mate !! ;)

#13 sg_frost

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Posted 24 August 2018 - 05:21 PM

Pulleys now modified to fit crank and camshaft. Blanking / oil seal plates to be made next.

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#14 sg_frost

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Posted 08 October 2018 - 04:56 PM

Bit of progress made lately. Plate roughly cut out for block and oil seal carrier made. Spacers made for cams to bring them flush with bottom pulleys. Jack shaft pulley modified so that the nut fits. Spacer for crank made. Head drilled for oil returns, and end blank piece welded and cut flush. Just the end plate for the head to be made.

The engine bay is closer to being finished. The door step has needed a little bit of fettling as it was welded slightly high at the front end. Sill ready to go on the drivers side, and then tackle the passenger floor.

Wipers are coming in for some attention, project Binky has a lot to answer for! I’ll be using BMW mini stalks and pier linkages adapted to fit this car. The headlight stalk has taken some re-wiring as it is supposed to run through a control unit, but all sorted now.

#15 sg_frost

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Posted 08 October 2018 - 05:14 PM

Front indicators have also now gone as I intend to have LED headlights with the indicators included.

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