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Mainstream Cooper Restomod, Germany

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#16 MaximMini

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Posted 03 February 2019 - 04:44 PM

Hi Everyone,

 

It has been some time since the last update :shy:. First I had no time, then I had to fight to regain access to my imgur account.

 

So, finally I have prepared everything so that the repair boot floor end can get in:

 

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Next I took the bracket from the tank strap from the remains of the boot floor but not before I drilled some holes to help identifying the position on the boot floor:

 

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Then it was time to finally fabricate the repair piece from scratch. Lots of cutting, bending and using a very basic dimple die, made from wood and using a socket, I ended up with this:

 

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That very much looks like I would be able to finally weld in the repair piece to the boot floor :D.

 

Another task I have to tackle soon is the repair of the threads in the subframe mounting rear panel. The two alternatives I'm currently think about are to either open the sill from the side or to open it up from the end and get some new nuts welded in 'Trev style' ;D .

 

Stay tuned for another update ..

 

Cheers from the Pied Pipers Town



#17 pete l

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Posted 04 February 2019 - 02:17 PM

Wow, brilliant panel work there.



#18 MaximMini

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Posted 10 February 2019 - 12:53 PM

Hi Everyone,

 

No progress this week unfortunately due to family commitments.

 

But I have made a great deal a pair of van rear doors. One is NOS but with some dents and corrosion from years of storage and another used one with a kink in the lower lip and some minor rust:

 

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I paid 170 Euro for both when picking them up locally.

 

Reminder to myself: Change storage place for parts - a damp garage is NOT good.

 

A 11 slat grill, some good used push rods and a pair of standard brake callipers are still in the post.

 

 

Cheers fro the Pied Pipers Town



#19 MaximMini

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Posted 10 February 2019 - 12:56 PM

P.S.: On the way to picking-up the doors I thought about how two van doors would fit in my trusty little Ford. Only to realise that Mini doors are mini doors :D .



#20 MaximMini

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Posted 17 February 2019 - 07:00 PM

Hi Everybody,

 

On Friday I jumped on the chance to spend some hours in the workshop. Unfortunately jumping in this case meant that I would not prepare myself as I usually do.

 

Firstly I forgot the repair panel for the boot floor which I had improved at home. So, there was no sense in working any more on the rear of the body.

 

Instead I focussed on the issue with the broken studs in the heal board. Some wire wheel action on the sills and a close look on the rear end of the sills lead to the decision to open the sills to get to the castellated nuts. Here are the sills the way they evolved over time:

 

I started wit the R/H sill

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The best aspect of MOD repair patches is that they can easily get peeled away with minor grinding action :D

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And the pre-fabricated repair patch, still missing the flute

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Then on with the L/H sill

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And the prepared repair patch

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I would have loved to continue with welding it all back together but unfortunately I had forgot the nuts to be welded in at home as well :shy: .

 

So on with another rust spot on the L/H side which I cut out

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Repair patch in place

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Then I had a cuppa of coffee which made me rethink my repair patch and made my redo it

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Hopefully this will spare me awkward grinding from inside the rear companion box.

 

Then I got carried away and forgot to take more detail pictures.

 

This is what I ended with before leaving for home

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Next I will make up a simple die to replicate the sill flute on this and any other repair patches to come. Watch this space ..

 

Cheers from the Pied Pipers Town



#21 MaximMini

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Posted 19 February 2019 - 07:05 PM

Hi Everyone,

 

Today I called it a day early and spend an hour in my basement workshop at home. The task of day was to make up a jig to reproduce the flute in the repair patch for the R/H outer sill.

 

This is what the jig looks like

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And this how it worked

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Which finally allowed me to produce this

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Looks OK to me ;D



#22 Wiggy

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Posted 20 February 2019 - 03:12 PM

That's flipping great!

#23 MaximMini

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Posted 24 February 2019 - 04:39 PM

Hi Everyone,

 

On Friday I send another five hours in the workshop and following last week's preparations, it was welding time. Priority has been to get the sill ends / toe board fixed so that the flintstone style beam axle could go on. Time to get the Mini off the hoist while I'm actually not working on it.

 

I started with the fixtures / cages I prepared to take the nuts for the subby screws.

 

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And the first one in at the L/H side

 

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All welded up and covered in weld through primer

 

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Next on was the R/H side where I finally used the repair patch with the flute, I recreated using the made up die tool

 

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Partially welded in

 

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And all done

 

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I'm by far no welding expert and even though with practise my welds are getting better, they still leave a lot to be desired.

 

Finally with the 'wood axle' in place

 

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Cheers from the Pied Pipers Town

 

P.S.: Heading in my basement workshop to fish a set of standard brake callipers and a cylinder head out of the citric acid bath, they took ..


Edited by MaximMini, 24 February 2019 - 04:42 PM.


#24 pete l

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Posted 25 February 2019 - 09:19 AM

That doesn't look strong enough to me. I'm sure there is more to it than a threaded piece of thick metal !



#25 MaximMini

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Posted 25 February 2019 - 12:33 PM

Hi Pete,

 

I take it that you are referring to my repair to the subframe mounting point in the heel board. It seems that my explanations aren't very clear, not helped by the fuzzy pictures.

 

What I did is fabricating a 'cage' of 5 mm steel to take a standard 5/16-inch hex nut. The hex nut can float axially in the cage and will be forced against the heel board outer sheet as per the original design as soon as the subframe bolt will be tightened up. This way it remains a force-fit as opposed to a from-fit connection.

 

Does that make sense to you?



#26 pete l

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Posted 25 February 2019 - 01:18 PM

So the cage is there ? I didn't see that bit.

 

So this piece of metal is just in place of the nut ? 


Edited by pete l, 25 February 2019 - 01:19 PM.


#27 MaximMini

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Posted 26 February 2019 - 07:13 AM

Pete,

 

May be a little sketch says more than a thousand words (in a foreign language)

 

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On the left the different 'layers' of the sandwich are shown from inner to outer while on the right I have tried a sectional view.



#28 MaximMini

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Posted 03 March 2019 - 06:35 PM

Hi Everyone,

 

Next week I will pick-up a short engine and drop two short engines (one for exchange and the original one from my Coper for rebuilt) and two cylinder heads at Faxe Wassong. In preparation, I dipped the cylinder heads in citric acid to clean the worth of the crust and rust off them.

 

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And while I was at it, I dipped the pair of standard brake callipers I snapped from eBay at the same time. They looked like the average set of old rusty callipers only to resurface very clean indeed.

 

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A light scrub with a brass wire brush. a degreasing and a surface prep later, I finished them off with some heat resistant black spray paint.

 

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Like new I would say ..

 

 

Cheers from the Pied Pipers Town



#29 MaximMini

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Posted 13 March 2019 - 11:20 AM

Hi Everyone,

 

Due to a cold that is bothering me for days, progress is slow these days.

 

The only I did on the body is to scape off some of the sound deadening on the L/H floor to get a better look what the corrosion looks like from inside the car.

 

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Not too bad I would say :D .

 

This is what the replacement short block, I picked-up from Detlef Faxe Wassong :D :D :D

 

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The specification reads as follows:

 

- block cleaned and inspected, bored and honed to +20"

- crankshaft bearing way (do you say so?) inspected and corrected

- upper face refaced

- NĂ¼ral pistons mounted on straightened low mileage rods

- rod foot measured and honed

- crankshaft ground (0.10/0.10), hardened, straightened, polished and balanced

- new ACL mains and big ends

- cam shaft bearings renewed

- new crank thrust washers

- surfaces primed

 

At the time of pick-up, I left an old Metro engine for exchange, the original Cooper engine for the same treatment as below as well as two heads for reconditioning.

 

Today a very important delivery arrived from England (one of my pre-Brexit purchases), which will help with the work on my Mini tremendously ;D

 

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Cheers from the Pied Pipers Town



#30 Nossedout

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Posted 13 March 2019 - 11:28 AM

Looking good!!

 

keep the photos rolling!







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