118 replies to this topic

[StuM]

Now, when it came to the trumpets and cones, I stumbled across an issue.  I'm going for Hi-Los, so just needed the cones.  One was already off and looked decent enough - I asked on this thread.  But the other was stuck fast to the trumpet (obviously had been on a long time).  I tried levering it off without luck.  I then tried to remove the knuckle joint - no joy there either.  In then end I soaked it overnight in penetrating fluid, then did this:

 

 

I was then able to whack the knuckle out.  I had a length of steel bar that was by chance just the right diameter, so I shoved it down the trumpet like this:

 

 

After some whacking, it came apart.  The cone also looks half decent so I might refit them - I would ideally swap all out for new, genuine ones but at £160 for the set I'm going to wait..

 

So, I hope that the next post will show the rear subframe built up ready for installation.

 

Cheers,

Stu

[StuM]

Every time I go to start this project, something gets in the way.  The latest annoyance was the rear subframe, which I paid to have powder coated.  After six months of sitting in a dry cardboard box, in a dry garage, I removed it to find lots of surface rust in the 'nooks and crannies'.  I sent it back to the powder-coater who apologised profusely and agreed to redo it.  It is now back with a much more comprehensive coat and looks great again:

 

 

So, I'll build it up next week.

 

The other annoyance is that I keep coming across parts that I didn't realise that I needed, so have been placing regular orders and now hopefully have enough to get on with.  My plan to have it rolling by the end of summer is out of the window, but with an optimistic hat on, I'm going to say that summer 2017 is the target.

 

I also misread the tax rules originally - I thought it became a tax-free classic in April 2017, but as it is a March car and the date for exemption is pre-January each year I have to wait until January 2018 for it to fall into the correct bracket.  Let's hope it is done by then......

 

I'm going to keep this thread running, but for non-TMF mates that want to follow I've also set up a Facebook page for the build at:

https://www.facebook...bby1100Rebuild/

 

Very light on content so far, but will rectify that soon.

 

Cheers,

Stu

Edited by StuM, 19 August 2016 - 10:58 AM.

[StuM]

Well, I've finally managed to start finding a bit more time to dedicate to this little, grey car.  First aim has always been to get the rear subframe built up and installed on the Clubby - I can then mount the wheels and have a look at the poke to determine which arches I need.  Once I know that I will buy them and have them sent to the sprayer to paint in Tweed Grey.

 

As previously mentioned, things have been delayed as I keep coming across fixings that I don't have - or more likely that are in the big, unlabeled tub of dirty fixings.  I have rectified that now buy laying out £90 on this:

 

 

http://www.ebay.co.u...mIAAOSwk1JWcuBZ

 

That lot should keep me going for a while.

 

I've pushed on with the subframe and have fitted new thrust washers and rubber seals (and bolts) to the radius arms - previously it had a real mix of old fixings that the previous owner had chucked on there.  The radius arms are all painted up and look good.  I need to make a note to grease them once fitted - I tested the nipples and channels while the spindles were on the bench and they work fine.

 

Someone noted when I put a picture up on my local Mini group's page that the handbrake quadrants had the wrong fittings:

 

 

Coach bolts.  So, I also bought new stainless pins and split pins, washers etc. 

 

Having fitted the Hi-Los and radius arms, plus new Goodridge flexi brake pipes, I then went to fit the hard (copper-nickel) pipes from the flexis to the drums.  At this point I opened my Automec kit and realised that although the pipes are all there and the right lengths, fitting etc - they need to be bent to the right shapes.  So, another pause while I ordered a pipe bender.  That has now arrived, so next up is bending the hard lines to shape.  Once that is done I'll be ready to fit the subframe to the car, which will mark a good milestone for me. 

 

Some photos:

 

 

 

 

 

 

 

 

 

 

[StuM]

Another update: the rear subframe is nearly completed.  I've fitted the new brake pipes up and it's all looking smart.  The pipe bender was really effective.  I have to say that the two pipes that connect from the flexi to the rear brake cylinders were quite tight.  They fit ok, but just had enough length versus others in the kit that have too much length.

 

 

 

 

And finally, just because they provide me with motivation, I had to stick a wheel on to see how they looked :)

 

 

So, I now need to double check everything is torqued up correctly and then find a dry day to install the rear subby - I could just about do it in the garage, but it'll be easier on the drive..

[StuM]

Milestone reached - rear subframe, radius arms and shocks now on the car, for the first time since it was painted.

 

 

 

I need to know the poke on the wheels to decide which, if any, arches are needed.  

 

 

 

 

Until it's dropped down off the stand I can't really tell.

 

One thing for next time - I will definitely fit the radius arms to the subframe AFTER fitting the subframe on the car - doing it the way I did meant that the front mount bolts were a pig to get passed the camber-adjust brackets and also meant that the whole lot was a heavy lump to lug around!

 

Now, onto the front....

[Vinay-RS]

Those wheels with that little bit of poke looks just perfect! 

[StuM]

It's time to start to think about the front subframe.  After much deliberation, I've decided to install the subframe first, then fit the engine at a later date (rather than build the engine up on the frame and lift the car over and on to it).

 

I'm still very torn on the mount options.  I had decided on (and have all new bit for) solid-mounting the whole lot - but keep reading people warning over cracked heelboards.  Really annoyed I didn't get spreader plates put in when the bodywork was done.  The floors are new, so it should be solid in that area.  I'm tempted to solid mount it and then fix the floor and put in spreader plates if I have an issue in future..

 

While I deliberate and wait for a window to start putting it all together, I'm doing a few jobs in preparation and getting the bits together.  For example, I sprayed up the new adjustable tie rods..

 

 

 

 

Edited by StuM, 05 October 2016 - 01:47 PM.

[StuM]

Whilst killing time, waiting for various fixings etc to arrive from Mini Spares to enable the front subframe build-up, I started to gather together stuff from the various boxes that came with the car.  Some of it had been cleaned and painted already, so just needed a wipe over.  Other bits needed a paint or repaint.

 

I have a can of Tweed Grey (GR4) that I had mixed up, so..

 

 

And the brake master cylinder:

 

 

The wiper motor got the same gunmetal coat as the tie rods (and now steering rack):

 

 

And here's a load of the bits looking much smarter:

 

 

I have a lot of brackets etc that I have no clue about so lots of trawling through tech diagrams to identify is needed.  If anyone can help with anything in the bottom left section of the picture, that would be appreciated - labelled 1-5 here:

 

 

A Mini Spares parcel arrived so, subframe build soon.

 

Cheers,

Stu

[phil hill]

1. Mount for distributor splash shield. Goes under the rocker cover bolts, missing the plastic locking clip.
2. Bulkhead cover plate for unused pedal box, with hole for heater hose to go through.
3. Coil mounting bracket. Fit coil to the bracket, then hang bracket over cylinder head stud nearest heater valve.
4. Upper Radiator mount. Fits between thermostat housing and radiator shroud. Different types for different engines.
5. Broken part of engine mount. Throw away !!

Phil.

[StuM]

That's brilliant - thanks for taking the time Phil.

[StuM]

 

I got fed up tripping over the steering rack, so decided that I might as well fit it to the car..

[StuM]

So, time to start building up the front subframe.  I've been doing some preparation work and stumbling across some more frustrations.

 

First up, the pivot pins for the bottom arms that I had acquired from the previous owners were all prepared and painted - but sadly they still had the metal bush sleeves from the old bushes more or less welded on to them.  On top of this, the thread had been damaged by a grinder when the old bolts were cut off.  All in all, it presented an issue for refitting, so much better to order a new pair.  I ordered a load of other bits and bobs at the same time.  

 

I bought them from Wood & Pickett, then etch primed:

 

 

Then painted them to match the shocks:

 

 

I started installing bits last night.  I had a bit of an issue with the upper arms - I followed what I perceived to be the best practice - fitted the thrust washer to the 'rear' (having removed the pin) and the rubber seal.  I then just had the rubber seal on the front... but it was a terrible fit and I ended up squashing and damaging the rubber seal.

 

Here is the 'rear':

 

 

And the front:

 

Note that the rubber seal is crushed and out of shape.

 

Looking at this last image, I fitted it without the rubber seal at the front and you can see the space left - not a lot. I've rested the seal on top just to demonstrate the difference.

 

 

Lots of head scratching later, it was getting late and cold in my garage, so I gave up and came indoors - and posted up on the forum.  The answer was quick and easy - a rookie error on my part, I'd put the thrust washers the wrong way round.  There is a thick one and a narrow one.  The thick one should be at the front, I'd put it on the rear.

 

I'll correct that tonight.  Anyway, it is looking good on the whole:

 

[StuM]

Front subframe time.  As with all jobs on this car, I looked and thought 'quick and easy' to get it up into the car, but was actually a bit of a pain - I say 'was', it still is..

 

I rolled the car out of the garage as it was a fine, sunny morning.  Shifting it around on the skate is becoming a ball-ache now that it has the subframes bolted on, so I need to get it on its wheels soon.

 

I rolled the front subframe in under the car on a trolley and all looked good...

 

 

 

I'd attached the lower rear (floor) mounts first, then the teardrops.  New stainless fixings on everything.  Once I had the jacks in place underneath, I started to slowly lift up the subframe... only to find that the new front panel that was fitted by the previous owner had a lip on the offside which meant that the subframe couldn't pass.  I lightly modified this bit and tried again, but couldn't get the subframe up past the teardrops.  In the end, I removed the tear drops and slotted them in after the subframe was in place.

 

So, the front subframe is now in place, fixed by the top bolts and the ones through the teardrops.  But, the lower ones are slightly out of alignment, so I'm going to have to loosen the other mounting points again and wiggle it around.  

 

At this point, it got cold and the clear blue skies had been replaced by angry, grey clouds - so I quickly shoved it all back in the garage.  But, it's progress.

 

 

I opted for two towing eyes as my OCD likes the symmetry of it!

 

 

And finally, I couldn't resist giving him more of a face temporarily

 

 

Next up - sort the mounting alignment, fit the hubs, connect the steering rack and fit the steering column...  I really need to get the wheels on to see which arches I need, so am pressing on to get to that point.

 

[mk1leg]

looking good its coming together nicely

[sixtyeight]

great build. love tweed grey!

 

I dread putting parts on a freshly painted car - so I'm doing mine backwards! painted underside, inside, boot, engine bay, and assembling most of the car, then will send the drivable car to the painters to have the exterior done! Also, I can't afford paint at the moment!