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Finally Got My New Project Home. 93 Cooper Spi.


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#16 exuptoy

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Posted 21 August 2020 - 09:57 PM

looks as though it's in fairly good nick?



In fairness John it’s pretty good. I think it’s had a bit of a resto some time back.

Today I decided to clean up a few components starting with the alternator which appears to be a Ford item (maybe an upgraded part?). I used a wire brush on the drill and then stuck it on the polishing mop on the bench grinder before masking the centre and end and giving it a light coat of etch primer then satin black.
Someone had sanded the top of the radiator header tank so I gave that a once over with the Solvol polish, before taking all the paint off the rad cowl, coating it with Kurust, then etch primed before satin blacking it. Then I stuck it all together and bolted it all back in. Following watching upbuildgarage videos I have purchased Fertan which seems to be similar stuff to Kurust so I’ll give it a shot once it arrives.

Already looking much better I think.

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Edited by exuptoy, 21 August 2020 - 10:33 PM.


#17 exuptoy

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Posted 22 August 2020 - 10:33 PM

Today I didn’t have much time to go up the man cave then found I had an hour spare a bit later so went up to at least do something today. As I’m replacing the scuttle panel I thought I’d remove the vin number from the original scuttle and let it into the new one. Not technically ringing the vehicle :D but something usually left out by most people. I just wanted it right when it’s complete. Took me a little while tweaking the power and wire feed but going forward it should be pretty close.


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#18 exuptoy

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Posted 27 August 2020 - 08:28 PM

Spent a fair while removing all the interior and glass to save it from damage whilst welding etc., then started to unpick the spot welds in the RHS window scuttle seam before chopping out the rust in that corner, but not before I made a cardboard template to make the new piece. Got it welded in place before linishing it all back with the B&D finger belt sander. Gave it a quick coat of Fertan rust converter to see how it pans out.
Very pleased with the outcome.

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#19 exuptoy

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Posted 28 August 2020 - 09:13 PM

Very impressed with the Fertan rust converter which seems far better that the old Kurust. It allows the steel to remain uncoated for up to 6 months before painting!
Got the old scuttle unpicked and treated, got the rotten section of flitch panel cut out which was like a sieve and with a bit of CAD (cardboard aided design ) made a new piece and welded it in place but only after repairing the piece behind which would eventually be plug welded to.
Then I cut out the rot from the passenger side window surround and replaced with a new piece of steel. New scuttle just sat on top in the last pic to see how it looks. It’s coming along.

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#20 nitrodave

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Posted 29 August 2020 - 07:21 AM

Top work! Good to see you making good progress!



#21 exuptoy

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Posted 29 August 2020 - 01:51 PM

Cheers Dave.

Today’s work was to reshape the closing panel to accommodate the scuttle, plug weld it in place and give it all a coat of Fertan rust converter then offered up the scuttle to check the fit is right. Next was to fit some brace pieces across the door once the door was removed to allow me to cut out the door frame and get rid of the rot. This driver side corner is the worse panel on the car! Made a start removing the door step, not much left of the lower ‘A’ pillar!

Not sure if the substantial piece at the bottom is meant to be fixed to the inner frame or just plug welded through the outer door frame?? Anyone? Be great if I had a pic of this area.

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#22 exuptoy

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Posted 30 August 2020 - 03:08 PM

Just pulled the trigger on a new upgrade! :D

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#23 exuptoy

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Posted 17 September 2020 - 09:50 PM

Made a start cutting out the sills yesterday. What a mess and multiple layers of rust. That’s the cost of oversills I guess.

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My sill/floor repair arrived from M-Machine.

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Made a start unpicking the spot welds along the door frame and pillar. Today I got that done and was able to test fit my new frame. Can’t weld it in just yet as I need to measure the upstand on the rear arch to sill repair when it arrives.

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#24 exuptoy

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Posted 18 September 2020 - 06:27 PM

Got my door on this morning which confirms the frame will fit just fine.
Next I removed the hinges and separated them, cleaned them up, cut off the snapped studs, drilled and tapped for 6mm and thread locked in 3 x stainless (one has been drilled too big the the PO), a couple of stainless nylocs mean I’ll be able to remove the door easier next time!

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Next I cut out the roof repair (again!!!) and this time following fitzee fabrications butt welding video on you tube I made my way around the patch with a 30mmx1mm Dremel disc set at 45 degrees I managed to get it in with minimal distortion. Very pleased with the outcome. Currently extending the drip rail so it can be spot welded to the roof gutter once the door frame goes in.

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#25 exuptoy

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Posted 19 September 2020 - 11:51 AM

This mornings work was to try and get a useable drip rail to weld into the gutter. It was a ball ache but looks acceptable. Once spot welded to the gutter and seam sealed (or should that be filler? ....anyone?) it’ll look grand.....and I’ve run out of gas! (Both argon and lite!)
In fairness the Heritage panel gutter at the front looks far too wide. I may need to reform the end where it comes round to meet the front gutter. I’ll do that one the drop rail to gutter weld is complete. It’ll give it more strength to beat it into shape.

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#26 exuptoy

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Posted 19 September 2020 - 06:51 PM

Closed my gutter up to where the frame should be.......door brace was stopping it going to the right place!

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Edited by exuptoy, 19 September 2020 - 06:51 PM.


#27 exuptoy

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Posted 23 September 2020 - 05:26 PM

Got my arch to door repair cut in, also shaped the sill section and cut back my door step. Not too happy with the Heritage panel as it seems to fall short of the sill line and lower door corner line. Something seems amiss. Probably have to make up a piece in the B pillar once it’s welded in. I have to make up the companion bin closing panel repair next then maybe I can fit the door frame.
My BMW panoramic roof also arrived from Kent BMW Mini Spares. That’ll be fitted in a few weeks once I’ve put some strength back in the shell. Collected both my Argon & Argoshield Light too so I can carry on.

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#28 sonscar

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Posted 23 September 2020 - 07:55 PM

Looks like a fine fettle will improve that nicely.I'm sure you have it covered but I would try the door before finalising the step position.Keep up the good work.Steve..

#29 exuptoy

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Posted 23 September 2020 - 10:29 PM

Cheers pal, I certainly will ;)

#30 exuptoy

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Posted 24 September 2020 - 05:14 PM

First things first was to tidy up the garage and my bench which I haven’t seen in about 4 months!
I then mounted my adjustable Heuer bench vice which was a freebie from work, then I welded a piece of angle to the clamping section of my shrinker/stretcher so I could mount it solidly for modifying panels as required.
Once my space was clear I cut out the rusty section from my companion box closing section and welded in a new piece (this Aldi rotary tool with extension and these little 30mm x 1mm discs is probably my favourite tool just now for accessing tight spaces).
Then I cleaned all weld faces on the door frame and painted with galv weld thru primer before masking the edges and etch priming and stuck some old topcoat on the pieces of frame which won’t be accessible once fitted. Weld time tomorrow.

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