61 replies to this topic

[Harry L]

Forgot about this thread, got lots of updates so will get to work updating this!

[Harry L]

Right some photos of the fabrication work now I can post again!

 

First they modified the inlet manifold to fit against the bulkhead. The runners are cut and re-welded at an angle. This is done so we don't have to make any modifications to the bulkhead itself, something I wanted to avoid. 

 

Radiator measured up and made. This is the biggest we could fit without causing clearance issues with the wheel/subframe. It looks small but the thick core actually gives it a larger capacity than a stock Civic radiator so should perform well. The bonnet will have holes in to aid airflow to it as well.

 

Offered up!

 

Header tank made up and a SPAL fan fitted, some plumbing in also done

 

 

Manifold all made up, this was such a tight fit and only has about 2mm of clearance. Who's idea was it to try and do this with a completely standard body shell? 

 

Gear selector shortened and bolted up, all gears select beautifully, you wouln't know you're not sat in an EK9!

 

Had to clearance the subframe in the process, a shame we had to do this as the subframe was expensive and is designed for this setup but there we go.

 

 

 

Onto the exhaust. I went with a single box setup with a 200 cell HJS cat. We don't need a cat by law on this setup but seemed a good idea to keep noise and smell down as much as possible.

 

Few photos of the finished product after I collected it

 

 

We are so so close to getting this on the road now, next priorities are getting the alternator fitted as well as the driveshafts. Then I'm going to concentrate on wiring and see what happens when I turn the key! Once I've got it running, it's just a case of fitting the interior and some finishing touches and we can start using it!

Edited by Harry L, 09 April 2022 - 09:28 PM.

[Harry L]

Quick trip up to Birmingham to see JB Auto Trimmings to pick up something rather special 

 

 

They've done an absolutely amazing job, I absolutely cannot wait to get it all fitted, it will compliment the blue exterior so well. I didn't have any interior at all, so they supplied the seats and trimmed them in tan leather with twin Bentley style diamond stitching. 

[Steve8274]

Really nice work and that trim looks fantastic.
Very close now

[johnR]

Some lovely fabrication work there - and a great interior - bet you can't wait to drive it!

[Harry L]

Realised I haven't updated this in forever, but the car is now running! Lots of progress has been made including fitting the alternator and driveshafts, neither of which are easy jobs and took a lot of time and tested my patience right to the limit!
 
Couple of Youtube videos linked below of its first start. At first, the idle was very erratic which we quickly diagnosed as an air leak at the inlet manifold. After tightening up the inlet manifold, the car now idles perfectly and sounds great!
 
First ever start - https://youtube.com/...Q?feature=share
 
Revving video - https://youtube.com/...s?feature=share
 
Idling perfectly once fixed - https://youtube.com/...8?feature=share 

 

https://youtu.be/KUdzQf6g69I

 

 
 
Going to get the body loom wired in this week and get the interior fitted, then it's just a few small jobs and it'll be ready to start driving 

Edited by Harry L, 31 December 2022 - 11:57 AM.

[sonikk4]

I have to say i was never really a fan of these conversions (each to their own i know) but i have to say these engines have so much potential its mad and your set up looks the mutts nuts.

 

More of a convert now especially when watching and following PFI Speed and BoostedBoiz on Youtube and seeing what can be done (and cant be in certain cirumstances)

 

Honda have built some engines over the years that take some serious abuse and power outputs especially if you put one of the little (or not so little) spiny sucky whistling things on (turbo or supercharger) Power outputs surpassing with ease most common sports cars (Porsche Ferrari etc) and big V8. Honda K20 and K24 engines with a turbo on, springs and retainers can see in excess of 600+ bhp with a Hondata ecu or Fueltech ecu. And its reliable power as well. Put a bit more effort into the engine build and away you go eclipsing power outputs that most of us would have thought crazy to achieve. What a scene to be involved in.

[Harry L]

I have to say i was never really a fan of these conversions (each to their own i know) but i have to say these engines have so much potential its mad and your set up looks the mutts nuts.

 

More of a convert now especially when watching and following PFI Speed and BoostedBoiz on Youtube and seeing what can be done (and cant be in certain cirumstances)

 

Honda have built some engines over the years that take some serious abuse and power outputs especially if you put one of the little (or not so little) spiny sucky whistling things on (turbo or supercharger) Power outputs surpassing with ease most common sports cars (Porsche Ferrari etc) and big V8. Honda K20 and K24 engines with a turbo on, springs and retainers can see in excess of 600+ bhp with a Hondata ecu or Fueltech ecu. And its reliable power as well. Put a bit more effort into the engine build and away you go eclipsing power outputs that most of us would have thought crazy to achieve. What a scene to be involved in.

 

I too was never really into engine swapped Minis at all, always thought if you want a Honda powered car then just buy a Civic   I even had machined and rebuilt a nice MG Metro 1275 engine which was ready to fit when I just had this horrible urge to fit a VTEC engine. I've never even driven an engine swapped Mini so this is a massive gamble that might go very wrong once I actually get behind the wheel! 

 

I have kept as much of the car as original as I can, no bulkhead mods, intact standard front end and still on proper cone suspension as I want it to feel as 'Mini' as it possibly can, albeit with a completely different character under the bonnet. 

[Harry L]

I'm not being very good at this build thread, thought I'd post a few photos of where we are up to now. 

 

 

Fitted the washer tank under the NSF wing, will have to wait and see if this has clearance issues with the tyre under compression but it looks okay

 

This is how the engine bay is looking now the alternator and air filter is fitted, currently remaking the loom and it can be fitted permenently

 

 

 

Rear brake lines made up

 

 

Rear brake lines being fitted, I'm not going to show you them as it's a bloody mess  

 

 

Garage doggo

 

 

Driveshafts built up and fitted, Japanese maintenance free balljoints waiting to go on

 

 

Rear foglight and bumper fitted

 

 

Front bumper and grille fitted

 

 

ONTO THE INTERIOR!

 

Parcel shelf mounted third brake light

 

 

Audio cables and front to rear loom fitted ready for the carpet

 

 

This is such a stressful job! I'm using the Optimise Automotive carpet which has about 20mm of foam on the backing so really difficult to get it in position, but the end result is lovely

 

 

Seats fitted

 

 

Very happy with my choice of a suede headliner!

 

 

Rear speakers fitted

 

And some doorcards

 

 

Was quite amused that the tyre of my daily is taller than the bonnet of the Mini!

 

 

Drove it down the drive to get some photos of it out in the open

 

 

Gave it a clean, and this is where we are at now

 

 

That's us up to date now, got a weekend of progress ahead where we will hopefully have the engine loom finished and wired in for good, then the clutch needs more bleeding and we can take it for a little shakedown! 

The next big thing to tackle is the wiring, we are going to wire the body loom from scratch as I've removed all traces of the original Mini wiring, then I'm going to make a dashboard we will be ready to finish all the little bits and pieces before it's ready for the road, it's going to be a fun summer of driving this thing 

[thelegg]

That's looking very tasty :)

[bartman]

very nice build, i started my 10 years ago still not finished it yet. Have you driven it yet?, how do you find it to drive?.

[Harry L]

very nice build, i started my 10 years ago still not finished it yet. Have you driven it yet?, how do you find it to drive?.

I've driven it about 10 meters to the end of my drive and turned it round! Here's a video of its first ever drive, this is when it had no throttle cable connected and only half a clutch 

 

https://www.youtube....rts/aTKDhI-1O84

 

 

One thing I noticed when I turned it round is the wheels catch on the arches big time, going to have to clearance it a bit but first I'm going to get the right height set correctly and also get an alignment as the wheels are all over the place! 

 

 

A set of Carbon Weezel arches will then be the very last thing once I'm happy with the right height and alignment.

[Harry L]

Another long time, no update! Things have been progressing with this and I'm much better at keeping my Instagram updated than this thread.

 

Firstly, finished building the engine loom, wrapped it all in loom tape and fitted it. This is pretty much the finished engine bay now.

 

 1.jpeg   53.01K   0 downloads

 

 2.jpeg   106.28K   1 downloads

 

Once this was all tested and confirmed everything engine wise worked properly, we started on the body loom. 

 

 4.jpeg   96.87K   1 downloads

 

 3.jpeg   78.49K   1 downloads

 

 15.jpeg   35.73K   0 downloads

 

This is a fully bespoke wiring loom designed just for this car. I was originally going to use a Mini loom, but after seeing how badly it is fused and the amount of wasted cable, I decided to build one from scratch. Everything that draws a significant amount of current is protected by a relay and no wire isn't fused! I've used all red or black 2mm or 1mm thin wall cable with two fuseboxes.

 

I'm almost complete with this now, just a few more circuits (horn, HRW and fog light) and it'll be ready for taping up. 

[Harry L]

Next up, the arches were bought and fitted. The wings needed a lot trimming off to stop the clearance issues. 

 

 9.jpeg   84.2K   0 downloads

 

 10.jpeg   59.57K   0 downloads

 

 

Trimmed the arches as well to reduce their width. 

 

 12.jpeg   58.62K   0 downloads

 

 11.jpeg   53.5K   0 downloads

 

 

Cut a couple of holes in the bonnet and fitted a bonnet lift kit from DSN, should help with airflow and keep the temps down in the summer

 

 14.jpeg   87.14K   0 downloads

 

 17.jpeg   60.63K   0 downloads

[Harry L]

Time for some woodwork, built a subwoofer enclosure for a 10" sub in the boot.

 

 5.jpeg   41.23K   0 downloads

 

 

Dashboard starting to take shape

 

 6.jpeg   53.63K   0 downloads

 

 26.jpeg   41.09K   0 downloads

 

 29.jpeg   86.92K   0 downloads

 

 30.jpeg   85.32K   0 downloads

 

 31.jpeg   55.28K   0 downloads

 

 32.jpeg   88.26K   0 downloads

 

 

Also wrapped the top dash rail in foamed backed Alcantara to match the dash

 

 23.jpeg   102.01K   0 downloads