68 replies to this topic

[littlewimp]

Nice work there Tupers , iv'e had my  1967 sandblasted this week and i'm just about to start the rebuild, i would say its in roughly the same state as yours  when you started.

Edited by littlewimp, 14 August 2015 - 09:32 PM.

[minimissions]

Those m machine a panel sections looking really good are those both sides of the a panel? So means you can just weld to the pillar and door post? Never seen those before?

You basically cut the old panel off at the step sill and A-post and then weld the new one rather just replacing the very outermost face of it. I'm not sure how long they've been making them but I've only found about them recently.   The first thing on the agenda for today was welding the crossmember strengtheners back in. This is where using spot weld drill bits comes in handy as all the parts already have the perfect size holes in them for plug welding.   Next up was rectifying the not uncommon sight of a snapped engine steady bar bracket.I'm not entirely sure how this happened considering the car was originally an 850 auto and would have bairly had enough power to pull the skin off of cold rice pudding.  A bit of grinding and few beefy plug welds latter and the new one's on. Hopefully it will last a little longer than the original. Moving slightly higher up on the front end there was a quite a heavily holed and pitted area on the top RH side of the bulkhead.   I started out by making a paper template of the various folds and creases on the panel before transferring it to steel.   I used a block of pine and a few different sized blunt chisels to beat the panel into shape and got it clamped up to check the fit.  As the panel was slightly larger than I had original planned I also added the indent for the tab that holds the wiring loom.  Then it got welded in.  A little linishing and some gentle planishing and it looks like this. I also made a new loom tab and plug welded it on.  On closer inspection the RH inner A-post also looked quite nasty so I decided it needed to go.   It's now out of the way and I'll get the new one in before the flitch goes on. 

Yeh was going to say I haven't seen those panels about either they look really good looking forward to seeing those fitted up etc.

Top work pal just love the repair plates you make just such nice neat tidy work :) it's really taking shape

[Van13]

I'm fairly new on here and still finding and learning how to do things on my project the way you take detailed photos especially of the a posts have made things much clearer. You are super talented and I look forward to your updates keep it up tuppers and thanks for the detailed photos they help the amateurs like my self loads

[Tupers]

The new A-post took a little bit of work at each end to get it fitting nicely but I got it welded on eventually.

 

The LH flitch only needed the MK3 wiper indent removing which sped things up a bit. 

 

 

After a lot of fitting, removing, drilling, welding and grinding the flitches are on which is a nice sight. 

 

 

I also salvaged the original radiator shroud and welded it on. 

 

The new front panel is a generic pre '76 part needs modifying to MK1 spec.

 

A MK1 front panel should have separate end sections in the grill opening so I made a template and transferred it to the panel before trimming the MK3 air vent piece away. 

 

 

I used an original end fillet as a template to make two shinny new ones. 

 

A few plug welds and a little linishing and it's looking like the real deal. 

 

 

Another piece that is incorrect on the new front panels is the size of the indicator plinth which was increased on the latter cars. Fortunately I kept the originals so that I could reinstate them. 

 

After trimming the excess steel from the old plinth I lined it up on the new panel and marked the section that I need to cut. 

 

I used an air hacksaw to cut the MK3 plinth off and sat the MK1 plinth in. 

 

The surrounding steel needed a little work with a hammer and dolly but eventually I got it sat flush all the way around and tacked in. 

 

Even more welding and linishing latter and the bulk of the MK1 conversion work is done. 

 

[minimissions]

Nice attention to detail there, getting those bits right make a great car at the end. :)

[Tupers]

Today was slam panel day.

Being a generic panel the holes for the bonnet buffer on the LH side are a bit rough and there was one too many holes on the RH side. 

 

 

After a bit of filing and welding they're back to how they should be. 

 

 

I had a bit of a dilema when it came to the centre of the slam panel where the bonnet latch bolts on. The holes would work despite being ovaled but the shape of the raised section isn't nearly as well defined as the original MK1 panel is.  

 

The centre of the original panel could have been cut out and welded into the new one but I thought I'd indulge in a but of fabrication and make a new piece starting with a card template. 

 

Here's the new piece after a lot of fiddling. 

 

A quick comparison between the three centre sections. 

 

It's now welded in and I think it looks very close to the original.

 

Having removed the slam panel brace earlier and I noticed that it was a different shape to the original one so I cleaned it up and reshaped it before reinstating it. 

 

 

Another flaw with the new panel was the lack of studs for mounting the horn so I made a new pair up using some 2BA screws and washers and brazed them on. 

 

 

The final piece in the puzzle was to add a sliver of steel to the centre of the grill opening as the new panel was higher than the original. 

 

 

Thanks for reading. 

[Jared Mk3]

You are capturing the details so nicely!

[Vinay-RS]

That panel that you manufactured is a thing of beauty! 

[Ben_O]

You gotta love all the small details. It makes all the difference

[Tupers]

Thanks guys, I enjoy doing all the little bits it's quite therapeutic. 

[jpw1275]

The new A-post took a little bit of work at each end to get it fitting nicely but I got it welded on eventually.

 
The LH flitch only needed the MK3 wiper indent removing which sped things up a bit. 

 

 
After a lot of fitting, removing, drilling, welding and grinding the flitches are on which is a nice sight. 

 

 
I also salvaged the original radiator shroud and welded it on. 

 
The new front panel is a generic pre '76 part needs modifying to MK1 spec.

 
A MK1 front panel should have separate end sections in the grill opening so I made a template and transferred it to the panel before trimming the MK3 air vent piece away. 

 

 
I used an original end fillet as a template to make two shinny new ones. 

 
A few plug welds and a little linishing and it's looking like the real deal. 

 

 
Another piece that is incorrect on the new front panels is the size of the indicator plinth which was increased on the latter cars. Fortunately I kept the originals so that I could reinstate them. 

 
After trimming the excess steel from the old plinth I lined it up on the new panel and marked the section that I need to cut. 

 
I used an air hacksaw to cut the MK3 plinth off and sat the MK1 plinth in. 

 
The surrounding steel needed a little work with a hammer and dolly but eventually I got it sat flush all the way around and tacked in. 

 
Even more welding and linishing latter and the bulk of the MK1 conversion work is done. 

Reminds me of a nipple transplant after a boob job hehe.......

As said superb attention to detail mate ...... Il be keeping all my bits I chop out and replace like the little box section on the mk3 a post rear the new ones don't have it where the thing goes through that stops your door opening to wide

Cheers james

[littlewimp]

Very Nice , you have set the standard for me to follow. 

[maryquant]

Some amazing skills here. I am in awe.

[Tupers]

Wow it's been a while since I've checked in! How about a little update?

 

The front panel and inner wings were done but before anything else could happen with the front end the doors needed repairing and the A-panels needed fitting. 

 

I started with the rather gammy front corner of the drivers door frame. 

 

 

The bottom of the frame was also pretty nasty so it got chopped out and I folded up a new section. 

 

 

From there it was a bit of simple welding and linishing. 

 

 

Now onto the full A-panels from M-Machine. They need a little tweaking around the edges but I got there in the end and they make for a much tidier job than the other panels available. 

 

 

Fortunately the passengers door was in a bit better nick and only needed some small repair sections making and a few pin holes welding up. 

 

 

More of the same for this side. The final door gapping wont happen until the rest of the front is on. 

 

 

The inner A-paenls and scuttle panel were up next after plugging the two spare wiper holes. 

 

 

So with the inner structure done it was finally time to get the front panel and wings fitted up. Not many pictures of this as I'm sure we all know what a Mini looks like. 

 

 

 

[Tupers]

The front's done but the rear panel still needed some love. The bumper rail had dissolved right the way across so it was time for more chopping. 

 

 

When I replace the boot floor at the start of this thread I had to remove the old loom tabs so I took this opportunity to reinstate some new ones. 

 

 

Then the new section of rear panel went in. 

 

I made my own corner sections by folding up some sheet steel and then curving them using my shrinker/stretcher. 

 

 

Once the shape was right the body was cut and the new corner sat in place. 

 

 

Same again for the other side. 

 

A little welding and linishing and they're on for good. 

 

 

 

I also made a little repair section for the bottom of the LH rear quarter. 

 

 

The final hole to fill was on the RH rear quarter so I cracked on with making a new section. 

 

After making a template and transferring the shape onto steel I turned the edge with a hammer and few different shaped blocks and trimmed it to size. 

 

 

 

Here it is after welding, linishing and DAing ready for some final finishing and then bodywork.