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Classic Mini Mayfair Restoration Project

roundnose

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#1 Fordy

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Posted 06 February 2019 - 10:52 PM

This is my first Mini Mayfair 1986 project that I purchased back in May 2016, I have posted some photos below.

 

I have done several items of work including new brake lines at the front, clutch, primary gear, gear linkage refurbishment. I shall post some photos in the near future.

 

Due to moving into my house, putting my time, effort and money into that, the Mini took a back seat.

 

As I was preparing the car for it's MOT with a slack handbrake, and then a no good rear brake cylinder. It soon turned into taking the rear subframe off as it looked rather rusty.

 

In the time of taking the rear subframe off the Mini I have now decided to do a full restoration to get the Mini to how a level/standard I am fully happy with.

 

It is now fully stripped down to a shell albeit for a few last parts; arches, bumper, couple of fixings. I shall again post photos of this in the near future.

 

Any advice is welcomed as I said previously this is my first Mini project.

 

33135037288_de73b80111_z.jpg1 by Samuel Ford, on Flickr

 

33135035498_742fa34f0e_z.jpg2 by Samuel Ford, on Flickr

 

47010339051_00fa88166a_z.jpg3 by Samuel Ford, on Flickr

 

33135034088_0f2c2f2a5e_z.jpg4 by Samuel Ford, on Flickr

 

40045760013_34e94209e0_z.jpg5 by Samuel Ford, on Flickr

 

46096473985_7b40ac2d60_z.jpg6 by Samuel Ford, on Flickr

 

40045758393_8a9ebc32b8_z.jpg7 by Samuel Ford, on Flickr

 

33135031878_3abd9f6dbf_z.jpg8 by Samuel Ford, on Flickr

 

46958515982_e3eda8e524_z.jpg9 by Samuel Ford, on Flickr

 

40045756033_921b62ded5_z.jpg10 by Samuel Ford, on Flickr

 

33135030688_936235db15_z.jpg11 by Samuel Ford, on Flickr

 



#2 Curley

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Posted 07 February 2019 - 02:07 AM

That's a beautiful shade of blue! Do you have any plans on fitting a trim seal between the body and wheel arches?



#3 Fordy

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Posted 07 February 2019 - 07:33 PM

It is a nice shade, will be changing the colour when I have it resprayed, thinking of going for a Nardo grey with black roof.

 

I hadn't, but will be replacing these when I come round to the rebuild.



#4 Fordy

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Posted 07 February 2019 - 08:42 PM

I've put a few photos together of some of the work I did before the handbrake cable and rear brake cylinder gave up on me.....

 

Fuel hose splitting, replaced with braided.

 

46295779254_4a346700a2_z.jpg12 by Samuel Ford, on Flickr

 

33144611068_b8b3167f45_z.jpg13 by Samuel Ford, on Flickr

 

From first buying the car the gear linkage seemed very loose, and difficult to find the gear with a lot of play. There was a lot of wear on the gear linkage shaft as well as being bent, the housing was heavily worn and perished rubber mounts. I had the housing machined to allow a bush to be fitted, a new shaft made, cleaned up/painted, new rubber mountings. All seen on the photos below. 

 

33144610388_26fa4122b5_z.jpg15 by Samuel Ford, on Flickr

 

46106113985_7e4b65f017_z.jpg16 by Samuel Ford, on Flickr

 

33144609178_c8b2d420e9_z.jpg17 by Samuel Ford, on Flickr

 

46106113575_52345a08f5_z.jpg18 by Samuel Ford, on Flickr

 

33144607848_e561184783_z.jpg19 by Samuel Ford, on Flickr

 

46106112945_1d7780dbf6_z.jpg20 by Samuel Ford, on Flickr

 

Removal of the air horn, was taking up a lot of space, wasn't a fan of the sound it made either.

 

46106111795_f4c38c19f7_z.jpg21 by Samuel Ford, on Flickr

 

46295770364_62f2bcf2ca_z.jpg22 by Samuel Ford, on Flickr

 

After resolving the issues with the gear linkage, I then was having issues with physically getting the car into gear. I was able to easily selected gears with the engine off. But with the engine on I couldn't select any, it was just hitting a brick all. I tried everything I could think of without having to strip down:

- Setup the clutch, including bleeding the system of any air

- Replaced the clutch master cylinder to slave cylinder hose, and re-bled the system.

- Replaced the slave cylinder due to split seal (see photo below)

 

Non of the above helped with the issue so I had to strip the clutch/flywheel housing down. Noticed a build up of a sticky oily material all over the clutch which was very damp. This was also found on the primary gear.

 

I then replaced both bushes on the primary gear, the primary gear seal, plunger and release bearing and clutch.

 

Once all back together and setting up the clutch again, this had removed the issue of getting the car into gear with the engine running with a nice firm feel to the clutch.

 

46106109965_a857b807f8_z.jpg23 by Samuel Ford, on Flickr

 

46106104585_322cf2b441_z.jpg24 by Samuel Ford, on Flickr

 

46106104095_f861cc534e_z.jpg25 by Samuel Ford, on Flickr

 

46295769314_48d29430df_z.jpg26 by Samuel Ford, on Flickr

 

47019911951_a2321b5d9d_z.jpg27 by Samuel Ford, on Flickr

 

32078659877_7a29bd3fb3_z.jpg20161004_103541 by Samuel Ford, on Flickr

 

47019910121_8a4f2ed8ee_z.jpg29 by Samuel Ford, on Flickr

 

46295766224_221e0286b1_z.jpg30 by Samuel Ford, on Flickr

 

46106105485_105e64d635_z.jpg31 by Samuel Ford, on Flickr

 



#5 Steve220

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Posted 07 February 2019 - 09:09 PM

Great start! How's the clutch now?

#6 Fordy

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Posted 07 February 2019 - 09:16 PM

The clutch was then fine after the work done.

 

I shall update tomorrow/weekend to bring up to speed where I am at.

 

I had a gap of a year and a bit of not touching the Mini due to moving into my house.

 

When I started the work again ran into a few other issues which has now lead me down the line of a full restoration.... 

 

I shall bring up to speed in the next few days!



#7 Fordy

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Posted 08 February 2019 - 08:32 PM

Couple of photos of the rear brakes which don't look in the best of condition.

46305997364_d8e16a3110_z.jpg33 by Samuel Ford, on Flickr

 

46305997804_bf417e688f_z.jpg34 by Samuel Ford, on Flickr

 

The rear subframe didn't look great, so decided to remove this to either restore or purchase a new one and build back up to refit. Few other photos of the condition it was in after being removed and as well as the radius arms.

32088476777_5396d0e84a_z.jpg35 by Samuel Ford, on Flickr

 

32088476377_6c2fb8c542_z.jpg36 by Samuel Ford, on Flickr

 

46305996334_624fc98e55_z.jpg37 by Samuel Ford, on Flickr

 

32088475087_cb87320196_z.jpg38 by Samuel Ford, on Flickr

 

32088479497_2f40325576_z.jpg39 by Samuel Ford, on Flickr

 

46305995964_994f3a3a2b_z.jpg40 by Samuel Ford, on Flickr

 

32088478967_b57b8c9797_z.jpg41 by Samuel Ford, on Flickr

 

46977984282_cb4258d747_z.jpg42 by Samuel Ford, on Flickr

 

32088477977_a6da184c3b_z.jpg43 by Samuel Ford, on Flickr

 

 



#8 Fordy

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Posted 08 February 2019 - 09:37 PM

With the rear subframe I made the decision to take the front subframe off which then later lead to me deciding to go down the fully restoration route after some thought.

 

As much as needed was removed from within the engine bay and all other items required to be disconnected as per the manual to free up as much room as possible for when lifting the body over the engine and subframe (with wheels still in place).

 

I had the back end sat on some large blocks and a scaffold board which I used as a pivot, sat a mattress under the rear to provide a little protection but unsure if that ended up helping and was more of a safety net if it was to slide back at all.

 

With all the nesseccary items removed and disconncted, the front was jacked up till it was high enough to wheel out the engine and subframe as one, with a trolley sat under the engine/gearbox and using the wheels to roll out as one.

 

46306255454_d80db05f4b_z.jpg44 by Samuel Ford, on Flickr

 

40065500813_c652d7bc9a_z.jpg45 by Samuel Ford, on Flickr

 

32088775887_5a408e01ee_z.jpg46 by Samuel Ford, on Flickr

 

33155059038_3b036f47cc_z.jpg47 by Samuel Ford, on Flickr

 

40065500763_afc0fcbed8_z.jpg48 by Samuel Ford, on Flickr

 

32088771407_d87fd04477_z.jpg49 by Samuel Ford, on Flickr

 

46306252394_2378b998eb_z.jpg50 by Samuel Ford, on Flickr

 

33155058948_2ce3dcf79c_z.jpg51 by Samuel Ford, on Flickr

 

When the body was lowered back down it was sat on blocks and a scaffold board as the back was, I made a trolley out of some other scaffold boards and 100m dia. trolley wheels to sit the body onto. So that I could now wheel the body in and out of the garage to free up some room when required.

 

46306249784_305d783931_z.jpg53 by Samuel Ford, on Flickr

 

As above with the body being able to be moved out of the way, the engine was removed from the subframe.

40065500653_02c9a0d71d_z.jpg54 by Samuel Ford, on Flickr

 

47030192401_f782f3376a_z.jpg55 by Samuel Ford, on Flickr

 

47030192751_e9c9018faf_z.jpg56 by Samuel Ford, on Flickr

 

47030193081_5097ffd956_z.jpg57 by Samuel Ford, on Flickr

 

Below are some photos of the body work which will require some attention, looking to get someone to take on the majority of this work for me.

Engine bay hood lip

47030193561_883595da27_z.jpg58 by Samuel Ford, on Flickr

 

Rear subframe mounts

32088787767_cdfc83d46f_z.jpg59 by Samuel Ford, on Flickr

 

32088789367_d6189f93fd_z.jpg60 by Samuel Ford, on Flickr

 

Rust on passenger  side arch/floor

47030191601_fc5a22d6e4_z.jpg61 by Samuel Ford, on Flickr

 

Engine bay/ inside bulkhead with wiring loom pulled through

32088774267_e5ec02a1ed_z.jpg52 by Samuel Ford, on Flickr

 

46116619545_e364c1cacd_z.jpg62 by Samuel Ford, on Flickr

 

Doors both side in simialr condition, DA back to see the rust damage 

33155067768_7d85d3a5b5_z.jpg63 by Samuel Ford, on Flickr

 

46116617265_f03f6c1639_z.jpg64 by Samuel Ford, on Flickr

 

Inside of the rear pocket companion box

32088779907_40aa80682c_z.jpg65 by Samuel Ford, on Flickr

 

46306258574_a6c63bc8a5_z.jpg66 by Samuel Ford, on Flickr

 

32088777587_4713373dca_z.jpg67 by Samuel Ford, on Flickr

 



#9 Nossedout

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Posted 13 March 2019 - 12:11 PM

Looking good!







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