86 replies to this topic

[DiscoDarren]

Here's some close ups of the rust and rot I found once I got the front A panels off and carpets out the front





I'm becoming more and more aware that this is turning into a full blown project. I came to the conclusion the only real way forward and for me to be able to tackle it is to strip the shell down to the point where I can flip it over. So I set about stripping all the engine electrics and bits necessary to lift the body off the front subframe.

[DiscoDarren]

I decided i would make it a lot easier for myself by taking off the carb, distributor, starter and radiator. I then took the front pipe off and the gear remote. Getting the roll pin out took absolutely ages, loads of swearing and I smashed my knuckles with the hammer on several occasions. But it's off now. I seem to recall it being about 2am so I packed in for the night. The following evening I racked by brains thinking of the easiest way to lift the body off on my own. The solution, albeit very primitive and dodgy looking, it worked a treat. I had a scaffold pole and put it across the beams in my garage roof to spread the load. I then used a heavy duty ratchet strap off of a HGV as a body hoist. I know it would of probably been easier to take the engine out first on its own, but I like a challenge. Lol

[rooney123]

yes I was the same with the roll pin lots of swearing the air as blue as summer sky then it dropped out but you learn looks like getting a lot done good for you...............................andy

[DiscoDarren]

On Friday I then set about removing the rest of the interior and flammable bits in ready ness for welding. Next on the agenda was to remove the rear subframe. It was the first time I had a proper look at it, because the previous owner told me it needed changing. I couldn't believe how bad it was, and this car had been on the road til 12 month prior. Anyway the first thing I did was to drain and remove the tank. While the tank drained I used my time to take off the rear lights. The tank came off in no time, as did the rear mounts. The forward mounts of the rear subframe however we're not quite as easy. I jacked it up and took off each wheel in turn to give me more access. Then played a little heat from my electric paint stripper. Brute force then won the battle. I replaced the wheel and did the same on the other side. I had Harry helping me ( that's Lisa's youngest son), he's 12 and wants to be a mechanic. He might change his mind before the minis finished tho. Anyway he was a great help and we had a really productive night.



That pretty much brings you up to date with my work for now

[DiscoDarren]

yes I was the same with the roll pin lots of swearing the air as blue as summer sky then it dropped out but you learn looks like getting a lot done good for you...............................andy

Thanks, should have been out there tonight really, but I wanted to get all my posts on here up to date. I'm getting to the point where I'm a little unsure what repair panels I need, so was hoping to throw it open to you guys on here. I'm gonna get some pics posted tomorrow all being well, to illustrate my dilemma. I'm unsure whether I need front floors or inner sills or both ?

[DiscoDarren]

Well just got cleaned up from a long day/night working on my mini project. Managed to get a few more bits done, albeit not as much as I hoped. I've stripped down the rear subframe, which is beyond repair, it took absolutely ages. I've not really got enough cash in my budget to buy a new one but I've managed to find one locally which is useable for now. I'm hoping to go and pick it up at the weekend. I know it might be false economy, but I'd rather spend my money on panels. A subframe will only be a weekends work when I eventually get the cash to replace it with a new one.

Once I eventually managed to get the radius arms off, I removed the drum, hub and back plate from both. I also hammered the pin out and removed the handbrake cable guide to make it easier to prep for paint. Both brake back plates are a bit worse for wear and I think I will buy some new ones. One wheel cylinder is brand new but the other has been leaking and needs replacing. I will also need to make up new brake pipes and replace the flexi's.

I managed to get both radius arms, both drums and a pair of the trunnions cleaned up with the wire wheel in my grinder. I then gave the said items a couple of coats of paint. Here's a before and after.





The pictures after one coat, but I gave them another for good measure. It's only hammerite, but I'm happy enough with how they've turned out, my cars never gonna be a show winner. I just want it to be solid and a tidy car. I'd be too scared to use it if I went for the straight out the showroom restore.

The only other thing I managed to do was scrape a load of that black gunk off the inside of the floors to try and see how far the rust goes. Will get the pictures posted on here later

[Ben_O]

wow what a project!

 

I am very surprised how bad this mini is! Mine was buried in a garden for years and isn't that bad!! LOL

 

Looks like you are making cracking progress and i will be following.

 

Nothing keeps your enthusiasm going like followers on here.

 

Good luck with it

 

Ben

[DiscoDarren]

wow what a project!
 
I am very surprised how bad this mini is! Mine was buried in a garden for years and isn't that bad!! LOL
 
Looks like you are making cracking progress and i will be following.
 
Nothing keeps your enthusiasm going like followers on here.
 
Good luck with it
 
Ben

Thanks for checking in Ben. Your right the forum does help keep the enthusiasm going, not to mention the help and guidance available on here too. I read a fair chunk of your thread, before I started mine, it's inspired me to try and fabricate a few parts where I think my skills will allow. I can only hope my metal work, welding, and ultimately my mini, turns out as good as yours.

As for the mini, I have to say its a heck of a lot worse than I expected, or budgeted for. I know it's usual to find a bit more than anticipated, but I think it must have been parked in a pond. Need a new knotted wire wheel for my grinder already. :) I have managed to get a bit more done since my last post on here tho. My phones on charge at the minute, but hopefully will get time to upload the picture tomorrow morning.

[colinf1]

I just read all this thread, now I'm dreading lifting my carpet to see what lies beneath.

 

Surprised at all the rust for a '93!

 

Keep up the good work!

[DiscoDarren]

I just read all this thread, now I'm dreading lifting my carpet to see what lies beneath.
 
Surprised at all the rust for a '93!
 
Keep up the good work!

.

Must admit its definitely caught me out. I would never have paid so much for it if I had realised. I was obviously aware of the condition of the wings and front panel. When I looked round prior to buying it I did lift the carpets and it looked sound. What I didn't realise was all the rust and holes hiding beneath the sound deadening/underseal stuff. Too late to worry about it now tho. Just need to make sure I do a good job so i get plenty of trouble free (expense free) years of motoring out of her. Anyway thanks for your interest Colin and I hope you don't find too many horrors when you lift the carpets

[DiscoDarren]

Can't believe its Friday night already. I've been that busy working on the car that I've neglected this build thread, sorry folks. Got a fair bit done tho. On Tuesday night after I uploaded the pictures of my radius arms, I had my usual fix of eBay and ordered a few mini bits. All stuff that I will need when I start to build my rear subframe back up. That's if I ever get time to fetch it.

Anyway with both sub frames now off I was keen to get the shell rolled over, to see what I'd let myself in for. However I thought it might be safest to get her braced up a bit before I lifted it and got carried away chopping bits off. I found a few bits of inch box hiding in the garage, that should do the trick. my girlfriend thinks I have an obsession for hoarding junk, but it pays off sometimes. I welded one across each door opening and then diagonally between the two. I intend to remove then replace one panel at a time, rather than chop all the rot out in one go, so I think think my bracing will be sufficient. Also I'm hoping it will be easier to get stuff to line up doing the repairs one by one.

So with a complete disregard for health and safety I lifted the shell up on my own and onto its side.



Bit of a hole near the subframe mountings.....think that May well be one of the items it failed its mot on prior to my purchase. Lol

[DiscoDarren]

Also after a poke about with the screwdriver I've got a few holes in the boot floor



Thought I better set about removing the rear valance to see if there were any more hidden surprises. I cut It off with a grinder then drilled out the spot welds and removed the flange as well. The valance closing panels and associated support bracket/stiffener were completely shot.





Particularly the N/S one which you can see had been gobbed up with fibreglass filler

[DiscoDarren]

Thursday morning the first of my ebay booty arrived. A rear wheel cylinder and a full set of poly bushes - not sure if I've done the right thing by getting these. I think I was more attracted by the fact that I could buy them as a kit and not have to worry about ordering all the rubbers separately as and when I needed them. Not too sure about them being bright orange either?



Thursday morning I also got a chance to see the result of my clean up effort in proper daylight. I had been out in the garage til way after midnight de-gunking the whole underside of the car. I did it in the hope that looking at some clean white solid bits of floor might cheer me up a bit. Also thought the neighbours might be a bit annoyed if I had been out there til 1am with the grinder chopping sills off. I wasn't at work Thursday day time so a chance to make some noise now and get the drivers side outer sill off.

Here's the floor looking fairly clean now





The inner sill has loads of rust. Luckily the passenger side doesn't seem as bad as this. Fingers crossed





The heel board ends not good either



I put a lot of this rot down to the fact that a new outer sill had been fitted but very little attempt to protect it with paint or underseal had been made. The other side of the car still has the factory fitted panels.

I've made a few enquiries elsewhere on the forum and now ordered some weld through zinc primer. I thought i could then use It to protect any good bare metal that i reveal as I continue removing the rot. That's about all I got done to the min on Thursday, because I've got another little project running along side this. I'm making a dj booth for the disco and I wanted to get it welded up to I could have a test fit of the star cloth we have bought.

[DiscoDarren]

Almost back up to date on here with my progress. I managed to get the car flipped over today and removed the passenger side outer sill. It certainly took a lot more getting off than the other one. This side of the car was still original, and a lot less rusty than the drivers side. I took about an inch off the bottom of the rear quarter too, I wanted to get a good look at the closing panel in the companion bin. It looks fine, as do the captive nuts and stiffener that the rear subframe mounts to through the headboard. I'm not sure if the end repair piece for the heel board come with that or if it's just the outer skin. I really must get some new panels ordered, but money is a bit of an issue at the minute - or the lack of it!!





Finally a picture of the passenger side inner sill taken from inside the car. I think a full length inner and outer sill is needed both sides of the car. Also door steps and lower part of the rear quarter between the door and wheel arch for both sides too. A lot more work and expense than I had bargained for.

[colinf1]

Making good progress! I dont know if I would have the courage or patience to go to that extreme of repairing rust. Keep it up!